Over Haul of Steamturbine

Electric Power Research Institute
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Guidelines for Reducing the Time and Cost of Turbine-
Generator Maintenance Overhauls and Inspections
Volume 1: General Practices
Effective December 6, 2006, this report has been made publicly available in accordance
with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S. Export
Administration Regulations. As a result of this publication, this report is subject to only
copyright protection and does not require any license agreement from EPRI. This notice
supersedes the export control restrictions and any proprietary licensed material notices
embedded in the document prior to publication.
EPRI Project Manager
A. Grunsky
ELECTRIC POWER RESEARCH INSTITUTE
Guidelines for Reducing the Time
and Cost of Turbine-Generator
Maintenance Overhauls and
Inspections
Volume 1: General Practices
1014730
Final Report, March 2007

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ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH
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Copyright 2007 Electric Power Research Institute, Inc. All rights reserved.

iii
CITATIONS
This report was prepared by:
Electric Power Research Institute (EPRI)
1300 W. T. Harris Blvd.
Charlotte, NC 28262
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Guidelines for Reducing the Time and Cost of Turbine-Generator Maintenance Overhauls and
Inspections, Volume 1: General Practices. EPRI, Palo Alto, CA: 2007. 1014730.

v
REPORT SUMMARY

Up to 70% of the outages planned for conventional steam power plants involve work on the
turbine. The challenge for the engineer is to improve performance and extend reliability, while
eliminating unproductive activities from the maintenance outage schedule. This report provides
general guidelines for planning and performing maintenance on steam turbines during outages.
Background
As a focus of innovative approaches and techniques, maintenance of aging steam turbines has
assumed increased importance. In 2003, coal-fired steam plants were an average of 32 years old,
and oil- or gas-fueled plants were an average of 36 years old. Many old steam plants, particularly
those that are coal fired and well maintained, can be positioned to succeed in the current
deregulated environment. To support this goal, EPRI is developing a series of engineering
guidelines, repair procedures, and support technologies. This report is part of that effort. It
contains guidelines to assist the turbine engineer in reducing the time and cost associated with
maintenance overhauls and inspections of turbine-generator systems. Planning and management
practices are described that are common to both nuclear and fossil units.
Objective
To provide general guidelines for planning and performing a steam turbine maintenance
outage
Approach
Under the direction of a Technical Advisory Group, the project team prepared a comprehensive
guideline and series of procedures to address the sequence of activities involved with planning
and performing a steam turbine maintenance outage. This information is available to members in
a four-CD set, to which information is added annually.
Results
This first volume of Guidelines for Reducing the Time and Cost of Turbine-Generator
Maintenance Overhauls and Inspections presents general practices for each of the fundamental
maintenance activities usually associated with an outage:
Operational turbine-generator condition assessment
Pre-outage planning and bidding
Unit shutdown procedures
Foreign material exclusion
Disassembly and recording clearances

vi
Turbine-generator condition assessment
Oil flushing
Rotor alignment and balancing
Pre-startup checks
Post-outage activities
Volume 2 of this report provides a series of detailed repair, replacement, and inspection
procedures to guide the pre-bid, inspection, disassembly, and repair of critical turbine-generator
components. Volume 3 provides balancing and alignment procedures for turbines, generators,
and exciters as well as an alignment primer and a balancing primer. Volume 4 provides turbine
blade/bucket, HP, IP, LP, and generator rotor and stator procurement specifications; generator
rotor and stator rewind specification; a turbine-generator major overhaul procurement
specification; and a turbine insulation specification. Volume 5 consists of a domestic and an
international turbine-generator engineering database containing unit-specific information.
Volumes 6 and 7 provide blade/disk design audit and inspection procedures for HP, IP, and LP
blades/disks.
Disk 4 of this set contains TGAlign V2.1 in both English units and SI units and their program
user manuals. TGAlign is an automated tool for turbine-generator bearing alignment.
EPRI Perspective
This guideline represents a significant collection of technical information related to maintenance
practices associated with an outage. The information in this report, collected by the projects
Technical Advisory Group which is made up of utility members, provides an important
compilation of information and procedures to be used by maintenance staff while they prepare
for and complete turbine-generator outages. As the current engineering and craft work force
continues to age and retire, taking their experience and knowledge with them, this document will
be of assistance in transferring the skill and knowledge of the current staff to new employees.
Keywords
Steam turbines
Maintenance
Outages

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ABSTRACT
Maintenance of aging steam turbines has assumed increased importance as a focus for reducing
costs associated with scheduled overhauls and inspections. Under the direction of a Technical
Advisory Group, EPRI has prepared a comprehensive guideline and series of procedures to
address the sequence of activities that are involved with the planning and performance of a
maintenance outage. Volume 1 consists of a comprehensive guide for operational turbine-
generator condition assessment and general practices for each of the fundamental maintenance
activities generally associated with an outage.

ix
ACKNOWLEDGMENTS
In 2004, the EPRI Guidelines for Reducing the Time and Cost of Turbine-Generator
Maintenance Overhauls and Inspections, Volume 1: General Practices was produced by
Generation Program 65.0 (Steam Turbine-Generator and Balance of Plant), Nuclear Program
Nuclear Steam Turbine-Generator Initiative (NSTI), and Technical Advisory Group (TAG)
members.
In 2005, sections 5.17.4.15.17.4.3 were contributed by Geoff Klempner and Isidor
Kerszenbaum, Operation and Maintenance of Large Turbo-Generators. 2004 The Institute of
Electical and Electronics Engineers, Inc.
The TAG members who assisted in the production of this report are:
Name Utility
Tom Alley Duke Power Company
Bob Bjune South Texas Project Electric Generating Station
Randy Bunt Southern Nuclear
Mitch Burress Tennessee Valley Authority
Greg Carlin Nova Scotia Power
Russell Chetwynd Southern California Edison
John Cizek Nebraska Public Power District
David Crawley Southern Company
Rick Dayton Progress Energy
Chris Essex Detroit Edison
Bob Garver First Energy
Tom Kordick Ameren
Bill McGinnis Reliant Energy
Scott McQueen Reliant Energy

x
Chuck Mendenhall Salt River Project
Tom Murray Salt River Project
Don Osborne Duke Power Company
Ken Palmer Pacific Gas and Electric Company
Ralph Pederson Nuclear Management Co.
Tim Scholl Tennessee Valley Authority
Philip Schuchter First Energy
Dave Sharbaugh First Energy
Ken Tillich Northern Indiana Public Service Co.
Generation Program 65.0, NSTI, and the TAG were supported in their efforts to develop this
guide by:
Turbine Technology International, Inc.
2024 W. Henrietta Road
Rochester, NY 14623
Principal Investigators
R. Dewey
M. Pollard
Sequoia Consulting Group, Inc.
9042 Legends Lake Lane
Knoxville, TN 37922
Principal Investigator
M. Tulay

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CONTENTS
1 TURBINE-GENERATOR CONDITION ASSESSMENT IN SERVICE............................... 1-1
1.1 Overview................................................................................................................... 1-1
1.2 Procedure and Objectives......................................................................................... 1-5
1.3 Planning a Steam Turbine-Generator Condition Assessment.................................... 1-6
1.4 Documentation of Condition Assessment .................................................................. 1-7
1.5 Condition Assessment Procedure ............................................................................. 1-7
1.5.1 Turbine-Generator History, Upgrades, and Major Forced Outage Events......... 1-9
1.5.2 Turbine Vibration .............................................................................................1-14
1.5.3 Bearing Metal and Oil Temperatures ...............................................................1-18
1.5.4 Thermal Performance......................................................................................1-19
1.5.5 Unit Start and Load Data .................................................................................1-25
1.5.6 Unit System Steam/Water Purity .....................................................................1-26
1.5.7 Lubricating Oil and EHC Fluid Testing.............................................................1-27
1.5.8 Pump Testing ..................................................................................................1-30
1.5.9 Turbine Steam Valve Test Results...................................................................1-31
1.5.10 Overspeed and Trip Checks.........................................................................1-34
1.5.11 Instrument Surveys ......................................................................................1-36
1.5.12 Generator Electrical Operating Data.............................................................1-38
1.5.13 Auxiliary Systems Data.................................................................................1-43
1.5.14 Component Visual Inspections .....................................................................1-46
1.5.15 Out-of-Limit Conditions and Upsets..............................................................1-47
1.5.16 Review/Update Turbine Generator Maintenance Plans ................................1-48
1.6 Evaluating Situations and Making Recommendations ..............................................1-48
1.7 Condition Assessment Example...............................................................................1-48
1.8 Summary Remarks ..................................................................................................1-52

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2 PRE-OUTAGE PLANNING AND BIDDING......................................................................... 2-1
2.1 Identifying and Establishing Engineering Responsibilities ......................................... 2-3
2.1.1 Engineering Responsibilities in a Major Outage Work Scope............................ 2-4
2.1.1.1 Pre-Outage Activities.................................................................................. 2-4
2.1.1.2 Outage Activities........................................................................................2-11
2.1.1.3 Post-Outage Activities ...............................................................................2-14
Post-Outage Meeting...........................................................................................2-15
2.1.2 Methods to Estimate Engineering Resources and Work Force Required.........2-16
2.1.3 Tasks Deferred to Reduce the Scope and the Potential Implications...............2-17
2.1.4 Tools Available and Input Needed to Define Tasks for a Scope of Work .........2-17
2.2 Pre-Bidding and Procuring Parts or Services (When Scope Is Defined) ...................2-18
2.2.1 Stationary Repairs - Diaphragms, Packing Rings, and Sealing Strips..............2-19
2.2.2 Blade/Bucket Replacement or Repairs ............................................................2-28
2.2.3 Bearing and Shaft Seal Repairs.......................................................................2-31
2.2.4 Generator Repairs...........................................................................................2-33
2.2.5 Valve Part Replacement and Repair................................................................2-36
2.2.6 Parts Stores Review........................................................................................2-37
2.2.7 Miscellaneous Turbine-Generator Exciter Parts, Bolts, Nuts, and Other
Parts................................................................................................................2-41
2.3 Identifying and Procuring Specialized Support .........................................................2-41
2.3.1 Lead Times to Arrange for Different Types of Support. ....................................2-42
2.3.2 Web Searches: Key Words or Identifiers to Produce Supplier Lists .................2-44
2.4 Scaffolding Requirements ........................................................................................2-44
2.4.1 Customization of a Scaffolding Plan ................................................................2-46
2.4.2 Ways to Reduce Scaffolding Erection Time.....................................................2-47
2.5 Safety Procedures....................................................................................................2-47
2.5.1 Plan for Insulation/Asbestos Identification, Handling, and Disposal .................2-48
2.6 Environmental Planning ...........................................................................................2-50
2.6.1 EHC Fluid........................................................................................................2-51
2.6.2 Waste Products to Be Considered...................................................................2-53
2.7 Crane Availability .....................................................................................................2-53
2.7.1 Crane Maintenance to Be Performed in Advance ............................................2-54
2.7.2 Types of Cranes ..............................................................................................2-54
2.7.3 Crane Use Schedule .......................................................................................2-55

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2.8 Turbine Deck Lay-Down Planning............................................................................2-55
2.8.1 Basic Elements for Any Deck Lay-Down Plan..................................................2-56
2.8.2 Basic Items or Issues to Be Reviewed.............................................................2-58
2.8.3 Items to Amend in a Customized Plan.............................................................2-59
2.9 Special Tools, Equipment, and Facilities ..................................................................2-59
2.9.1 Storage and Work Space Provisions for Cleaning and/or NDE........................2-61
2.9.2 Provisions for Cleaning and Inspecting Different Turbine Parts .......................2-61
2.9.3 Items or Issues Specified as Part of the Work Order for Vendors ....................2-63
2.10 Machine Disassembly Plan..................................................................................2-64
2.10.1 Basic Elements in the Machine Disassembly Plan........................................2-64
2.10.2 Issues or Items Reviewed ............................................................................2-64
2.10.3 Identifying Contingency Plans for Unexpected Work ....................................2-66
2.11 Foreign Material Exclusion ..................................................................................2-66
2.11.1 Organizational Responsibilities for Turbine-Generator Contracts .................2-66
2.11.2 Areas of the Turbine-Generator to Protect ...................................................2-70
2.11.3 Measures to Take for Each Critical Area......................................................2-71
2.11.4 Implementation of FME Plans for Turbine-Generator Work..........................2-73
2.11.5 Performance of Work Inside the Turbine-Generator FMEA..........................2-74
2.11.6 Retrieval of Foreign Objects.........................................................................2-79
2.11.7 Video Inspection of Shells and Steam Lines ................................................2-79
2.12 Training...............................................................................................................2-80
2.12.1 Training Formats..........................................................................................2-80
2.12.2 Recommended Training Topics ...................................................................2-81
2.12.3 Training Options...........................................................................................2-83
2.13 Rigging, Special Tools, Parts, and Expendable Materials....................................2-83
3 UNIT SHUTDOWN............................................................................................................... 3-1
3.1 Pre-Outage Testing................................................................................................... 3-1
3.2 Generic Steps for Shutdown...................................................................................... 3-3
3.3 Critical Engineering Concerns................................................................................... 3-4
3.4 Parameters to Monitor............................................................................................... 3-5
3.5 Opportunities to Reduce Shutdown Time.................................................................. 3-7
3.6 Practices That Have Been Used to Reduce Shutdown Time..................................... 3-7
3.6.1 Overspeed Trip Testing .................................................................................... 3-9
3.6.2 Electrical Trips vs. Mechanical Trips................................................................. 3-9

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3.6.3 Boiler/Reactor Feed Pump Turbine Controls ...................................................3-10
3.7 Removal of Covers and Crossover Piping................................................................3-10
3.8 Valve Disassembly...................................................................................................3-11
3.9 Practices to Accelerate Cooling................................................................................3-12
3.10 Operations Performed During Turning Gear Operations...........................................3-12
3.11 Lubrication Oil Blanking............................................................................................3-15
3.12 Removal of Insulation...............................................................................................3-16
3.13 Lagging Removal .....................................................................................................3-16
4 DISASSEMBLY AND RECORDING CLEARANCES .......................................................... 4-1
4.1 Planning Lay-Down Areas......................................................................................... 4-1
4.1.1 Material Handling Methods and Considerations................................................ 4-3
4.1.2 Component Disassembly Requirements........................................................... 4-3
4.1.3 Component Work Scopes and Work Centers ................................................... 4-3
4.1.4 Component Weights and Floor Loading............................................................ 4-7
4.1.5 Tooling/Support Locations ................................................................................ 4-9
4.1.6 Power/Air/Water Requirements .......................................................................4-10
4.1.7 Personnel Needs (Restrooms, Eating Facilities) ..............................................4-10
4.2 Features of the Basic Rigging Plan ..........................................................................4-11
4.2.1 Rigging/Lifting Drawings for Major Components ..............................................4-11
4.2.2 Rigging Devices, Lifting Bars, Wire Rope, Synthetic Slings, and Shackles ......4-14
4.2.3 Practical Methods for Efficient Handling of Certain Components .....................4-16
4.2.4 Special Turbine Tools......................................................................................4-17
4.3 Scheduling Overhead Crane Time ...........................................................................4-18
4.4 Moving Without the Overhead Crane .......................................................................4-18
4.5 Special Storage Considerations ...............................................................................4-18
4.5.1 Racks for Diaphragms .....................................................................................4-19
4.5.2 Valve Stands, Rotor Stands, Mandrels, Try Bars, and Stub Shafts..................4-21
4.5.3 Shell Racks, Supports, and Cribbing ...............................................................4-23
4.6 Bolt Removal Practices and Techniques ..................................................................4-25
4.6.1 Identifying the Necessary Personnel for Unbolting the Turbine-Generator.......4-27
4.6.2 Available Tools Needed...................................................................................4-28
4.6.3 Useful Tools and Techniques for Different Applications...................................4-30
4.6.4 Bolt Removal Sequence ..................................................................................4-30
4.6.5 Required Inventory of Bolts .............................................................................4-33

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4.7 Taking Axial and Radial Clearances and Their Use..................................................4-34
4.8 Required Rotor Radial Position and Coupling Alignment Checks.............................4-38
4.9 Checks to Assess Spare Rotor Compatibility ...........................................................4-40
5 TURBINE-GENERATOR CONDITION ASSESSMENT....................................................... 5-1
5.1 Cleaning Without Disassembly.................................................................................. 5-2
5.2 Recommended Inspection and Testing Techniques.................................................. 5-3
5.2.1 Proof Test......................................................................................................... 5-8
5.2.2 Megger Test ..................................................................................................... 5-9
5.2.3 Doble Test .......................................................................................................5-10
5.2.4 Other Tests......................................................................................................5-10
5.3 In Situ Inspection......................................................................................................5-12
5.3.1 Economic Incentives Imposed by Deregulation................................................5-12
5.3.2 Machine Access ..............................................................................................5-13
5.3.3 Video Probe Systems ......................................................................................5-14
5.3.4 Utility Experiences...........................................................................................5-15
5.4 Accelerating Different Types of Inspections..............................................................5-16
5.4.1 Defect Sizing and Implications of Results ........................................................5-17
5.5 Cleaning Coated Versus Non-Coated Parts .............................................................5-19
5.6 Coating-Removal Techniques ..................................................................................5-20
5.7 Sampling and Analyzing Deposits ............................................................................5-20
5.8 NDE of Turbine-Generators and Collecting Boresonic Data.....................................5-21
5.8.1 Turbine-Generator Nondestructive Evaluation Techniques..............................5-21
5.8.2 Collecting Boresonic Data ...............................................................................5-22
5.8.3 EPRI-Supported Rotor Boresonic Inspection...................................................5-24
5.8.4 Boresonic System Evaluation Procedures .......................................................5-25
5.8.5 Inspection of Boreless Rotors..........................................................................5-26
5.8.6 Inspection of Steam Turbine Disk Blade Attachments......................................5-26
5.8.7 Inspection of Nonmagnetic Generator Retaining Rings....................................5-28
5.9 Inspection of Shrunk-On Components......................................................................5-28
5.10 Bearings Journal and Thrust Types.......................................................................5-29
5.11 Stationary Components............................................................................................5-34
5.12 Buckets/Blades ........................................................................................................5-40
5.13 Rotors ......................................................................................................................5-43
5.13.1 Causes of Rotor Bowing...............................................................................5-43

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5.13.1.1 Severe Rubbing.......................................................................................5-43
5.13.1.2 Bows Caused by Water Induction............................................................5-46
5.13.1.3 Bows Caused by Metallurgical Problems.................................................5-46
5.13.1.4 Corrective Actions ...................................................................................5-46
5.13.2 Other External Rotor Problems.....................................................................5-47
5.14 Shaft Seals..............................................................................................................5-48
5.15 Valves .....................................................................................................................5-51
5.15.1 Stop Valves..................................................................................................5-51
5.15.2 Control Valves..............................................................................................5-52
5.15.3 Reheat Stop Valves......................................................................................5-53
5.15.4 Non-Return Valves.......................................................................................5-53
5.16 Casings, Steam Chests, and Nozzle Chests............................................................5-54
5.17 Generator ................................................................................................................5-57
5.17.1 Classifications ..............................................................................................5-57
5.17.2 Generator Stator...........................................................................................5-58
5.17.3 Generator Field ............................................................................................5-62
5.17.4 Generator Electrical Testing.........................................................................5-66
5.17.4.1 Generator Stator Core Electrical Tests ....................................................5-71
5.17.4.2 Generator Stator Winding Electrical Tests ...............................................5-89
5.17.4.3 Generator Rotor Electrical Testing.........................................................5-105
5.18 Excitation System..................................................................................................5-119
5.19 Using Data on Condition Assessment to Assess Risk of In-Service Failure..........5-120
6 OIL FLUSHING.................................................................................................................... 6-1
6.1 Preparations and Precautions for Flushing the System............................................. 6-1
6.2 Resources That Should Be Available While Flushing................................................ 6-3
6.3 Precautions While Flushing....................................................................................... 6-4
6.4 Oil Cleanliness Criteria.............................................................................................. 6-5
6.5 Heating and Cooling the Oil Without Damaging the Bearing...................................... 6-8
6.6 Minimizing the Use of External Piping While Flushing............................................... 6-9
6.7 Flushing Without an External Filter...........................................................................6-10
6.8 Techniques to Get Maximum Flow Through Piping ..................................................6-11
7 ROTOR ALIGNMENT AND BALANCING........................................................................... 7-1
7.1 Different Tight Wire Techniques................................................................................ 7-1

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7.2 Information Collected from the Unit ........................................................................... 7-4
7.3 Automated and Semi-Automated Alignment Processes ............................................ 7-5
7.4 Slow-Speed Versus High-Speed Balancing............................................................... 7-6
7.4.1 Slow-Speed Balance Requirements/Considerations......................................... 7-8
7.5 When Spin Balancing Is Required............................................................................. 7-9
7.6 On-Line Balancing Devices ......................................................................................7-11
7.7 Potential Consequences of Not Balancing the Rotor ................................................7-12
7.8 Selecting Vibration Limits.........................................................................................7-13
7.9 Balance Limits..........................................................................................................7-14
7.10 Access to Turbine-Generator Rotors........................................................................7-17
7.11 Turbine-Generator Balance Support.........................................................................7-18
7.12 Turbine-Generator Balance Weights ........................................................................7-20
7.12.1 Split-Weight Design Dovetail Weights ..........................................................7-20
7.12.2 Tungsten-Style Weights ...............................................................................7-22
8 PRESTARTUP CHECKS................................................................................................... 8-1
8.1 Steps to Minimize Startup Time................................................................................. 8-1
9 POST-OUTAGE ACTIVITIES .............................................................................................. 9-1
9.1 Post-Overhaul Engineering Reports.......................................................................... 9-1
9.2 Documentation for Vendor Signoff ............................................................................ 9-7
9.3 Issues to Review for Future Planning........................................................................ 9-8
9.4 Recommendations for Planning Future Outages......................................................9-11
9.4.1 Problem Description ........................................................................................9-11
9.4.2 Solution ...........................................................................................................9-12
9.5 Inventory Decision Making .......................................................................................9-12
9.6 Integration with Maintenance Management Systems ...............................................9-13
10 REFERENCES .................................................................................................................10-1
A CONDITION ASSESSMENT DATA SHEETS..................................................................... A-1
B TURBINE-GENERATOR OUTAGE REPORT..................................................................... B-1
B.1 Outage Report Instructions ....................................................................................... B-1
B.2 Report Table of Contents .......................................................................................... B-3
B.3 Blank Report Format ................................................................................................. B-6

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C DATA SHEETS................................................................................................................... C-1
D FOREIGN MATERIAL EXCLUSION GUIDANCE ............................................................... D-1
D.1 Introduction and Purpose.......................................................................................... D-1
D.2 Definitions................................................................................................................. D-2
D.2.1 Glossary of Key Terms..................................................................................... D-2
D.2.2 Categorization of FME Areas ........................................................................... D-6
D.2.3 Categorization of FME Events.......................................................................... D-6
D.3 Plant/Station Responsibilities.................................................................................... D-8
D.3.1 FME Responsibilities for All Personnel............................................................. D-8
D.3.2 Typical Individual FME Responsibilities ........................................................... D-8
D.4 Establishing and Implementing FME Program Requirements ................................. D-11
D.4.1 Introduction.................................................................................................... D-11
D.4.2 General Programmatic Guidance................................................................... D-13
D.4.3 Sources of Foreign Material Contamination ................................................... D-13
D.4.4 Defining the Scope of Equipment Controlled by FME Procedures.................. D-14
D.4.5 Training and Qualification of Individuals......................................................... D-15
D.5 Developing and Implementing FME Control Plans.................................................. D-16
D.5.1 Factors to Consider When Developing an FME Control Plan......................... D-16
D.5.2 Typical Contents of an FME Control Plan ...................................................... D-17
D.5.3 Establishing the FMEA................................................................................... D-19
D.5.4 Determining Appropriate FME Controls for the Area ...................................... D-20
D.5.5 Establishing an FMEA Boundary.................................................................... D-21
D.5.6 Installing the FMEA Boundary........................................................................ D-21
D.5.7 Conducting Pre-Job Briefings ........................................................................ D-22
D.6 Performance of Work Inside the FMEA................................................................... D-22
D.6.1 FMEA Entry Requirements ............................................................................ D-22
D.6.2 Use of Control Logs ....................................................................................... D-23
D.6.3 Monitoring the FMEA ..................................................................................... D-25
D.6.4 Cleanliness and Readiness Inspections......................................................... D-26
D.6.5 Performance of Maintenance Activities Within the FMEA............................... D-26
D.6.6 Examples of Good Work Practices Inside the FMEA...................................... D-28
D.6.7 Implementing Graded FME Controls.............................................................. D-30
D.6.8 Ensuring Cleanliness Inside the FMEA.......................................................... D-31
D.6.9 Use of FME Devices ...................................................................................... D-33

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D.7 Recovery of Loss of FMEA Control......................................................................... D-37
D.7.1 Initiation of a Condition Report ....................................................................... D-37
D.7.2 FME Recovery Plan....................................................................................... D-38
D.7.3 Foreign Material Retrieval .............................................................................. D-38
D.7.4 Recovering Foreign Material After Returning the System to Service.............. D-40
D.8 Close Out of a Foreign Material Exclusion Area...................................................... D-40
D.9 References............................................................................................................. D-41

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LIST OF FIGURES
Figure 1-1 Example of the Form Used to Rate the Final Condition of the Turbine-
Generator ........................................................................................................................ 1-3
Figure 1-2 Example of NERC-GAD List of Maintenance Outage Events for a Typical Unit.....1-13
Figure 1-3 Typical Orbits Showing Different Problems ...........................................................1-17
Figure 1-4 Location and Function of Basic Turbine Controls ..................................................1-32
Figure 1-5 Location of Typical Turbine Supervisory Instrumentation ......................................1-36
Figure 1-6 Typical Generator Capability Curve.......................................................................1-39
Figure 2-1 Example of an Outage Plan ................................................................................... 2-7
Figure 2-2 Sample of Engineering-Supported Activities .........................................................2-13
Figure 2-3 Dimensional Requirements That May Be Provided Within a Repair Procedure.....2-21
Figure 2-4 Major Repair Times per Inch of Partition Radial Height .........................................2-23
Figure 2-5 Estimate of Total Major Repair Time per Partition.................................................2-24
Figure 2-6 Estimation Tool for Minor Partition Repairs ...........................................................2-25
Figure 2-7 Total Diaphragm Repair Time Divided by the Nonproductive Time .......................2-26
Figure 2-8 Plot to Track Consumable Costs vs. Productive Labor Costs................................2-27
Figure 2-9 Change in HP Section Efficiency After Four Separate Outage Periods .................2-28
Figure 2-10 Examples of Rotor Weight and Coupling Geometry Measurements....................2-32
Figure 2-11 Examples of Shells Used to Bridge Between the Retaining Ring and Rotor ........2-34
Figure 2-12 Part Location Information....................................................................................2-39
Figure 2-13 Four-Level Part Location Hierarchy.....................................................................2-39
Figure 2-14 Types of Lifting Cranes .......................................................................................2-54
Figure 2-15 FME Organizational Structure for T-G Contracts.................................................2-67
Figure 3-1 Section Efficiency Change During the Course of Three Outages ........................... 3-2
Figure 3-2 Example of Access Platforms................................................................................3-11
Figure 3-3 Plot of Shutdown Activities....................................................................................3-14
Figure 3-4 Plot of Accelerated vs. Non-Accelerated Cool-Down Rates ..................................3-15
Figure 3-5 Example of a Toggle Blank ...................................................................................3-16
Figure 4-1 Example of a Work Center Lay-Out Plan ............................................................... 4-4
Figure 4-2 Lay-Out Plan with Work Center Layouts to Match the Expected Work Scope ........ 4-6
Figure 4-3 Example of Loading a Reference for a Turbine Deck ............................................. 4-9
Figure 4-4 Example of a Lifting Drawing.................................................................................4-12
Figure 4-5 Example of a Detailed Rigging and Lifting Drawing...............................................4-13

xxii
Figure 4-6 Rigging Fixtures for CRVs.....................................................................................4-14
Figure 4-7 Rigging Fixture for a Control Valve Actuator .........................................................4-15
Figure 4-8 Modification to a Lifting Beam That Allows the Turnbuckle to Remain
Attached While Lifting.....................................................................................................4-15
Figure 4-9 Example of a Generator Field Support Modification ..............................................4-16
Figure 4-10 Example of a Diaphragm Transport and Storage Rack .......................................4-19
Figure 4-11 Example of an Oil Deflector Rack........................................................................4-20
Figure 4-12 Example of a Fixture Holding a Control Valve .....................................................4-21
Figure 4-13 Example of a Fabricated Rotor Stand with Rollers ..............................................4-22
Figure 4-14 Example of a Bearing Fitting Mandrel to Check Tilt Pads....................................4-22
Figure 4-15 Example of a Mandrel to Check Cylindrical or Elliptical Bearing Bores................4-23
Figure 4-16 Example of a Rack for Holding an HP Upper Shell..............................................4-24
Figure 4-17 Example of a Fabricated Shell Support ...............................................................4-24
Figure 4-18 Example of a Support for Generator Field Removal Without Cribbing.................4-25
Figure 4-19 Coupling Alignment Nomenclature......................................................................4-39
Figure 5-1 Access Path for Video Probe Delivery Device.......................................................5-13
Figure 5-2 Examples from Remote Video Probe In Situ Inspection ........................................5-15
Figure 5-3 Elliptical Bearing Construction...............................................................................5-31
Figure 5-4 Diaphragm Construction .......................................................................................5-35
Figure 5-5 Mechanics Describing Rubbing Process ...............................................................5-44
Figure 5-6 Typical Non-Return Valve Construction ................................................................5-54
Figure 5-7 Terminal Stud Hydrogen Seal Construction ..........................................................5-64
Figure 5-8 Location Susceptible to High-Cycle Fatigue and Low-Cycle Fatigue in Certain
Main Lead Designs.........................................................................................................5-65
Figure 5-9 Flux Fault Current Path.........................................................................................5-72
Figure 5-10 EL-CID Excitation Setup .....................................................................................5-73
Figure 5-11 EL-CID Analog Equipment ..................................................................................5-74
Figure 5-12 EL-CID Digital Equipment ...................................................................................5-75
Figure 5-13 EL-CID Chattock Theory.....................................................................................5-76
Figure 5-14 EL-CID MMF Theory...........................................................................................5-77
Figure 5-15 EL-CID Signal Interpretation ...............................................................................5-79
Figure 5-16 Toroid Wrap........................................................................................................5-82
Figure 5-17 Operating Flux Pattern........................................................................................5-82
Figure 5-18 B-H Curve Example ............................................................................................5-84
Figure 5-19 Flux Test Electrical Setup ...................................................................................5-85
Figure 5-20 Flux Test Mirror Setup.........................................................................................5-85
Figure 5-21 Infrared Hot Spot Bruce 7.................................................................................5-86
Figure 5-22 Infrared Hot-Spot Flux Test 1..............................................................................5-86
Figure 5-23 Infrared Hot-Spot Flux Test 2..............................................................................5-87

xxiii
Figure 5-24 Flux-Temperature Profiles...................................................................................5-88
Figure 5-25 IR Versus Temperature.......................................................................................5-92
Figure 5-26 Polarization Index Dryness Curve.......................................................................5-93
Figure 5-27 IR Versus Temperature PI................................................................................5-95
Figure 5-28 DC Ramp............................................................................................................5-97
Figure 5-29 Stator Hi-Pot Arcing ............................................................................................5-99
Figure 5-30 LKV G5 EE Hoseglow.......................................................................................5-100
Figure 5-31 PD Off-Line Capacitive Coupling.......................................................................5-101
Figure 5-32 Dissipation Factor Tip-Up..................................................................................5-104
Figure 5-33 NO Shorted Turns Traces Superimposed ......................................................5-109
Figure 5-34 NO Shorted Turns Traces Separated.............................................................5-109
Figure 5-35 NO Shorted Turns Traces Summed...............................................................5-109
Figure 5-36 RSO Single-Shorted Turn Dual Superimposed Trace ....................................5-110
Figure 5-37 RSO Single-Shorted Turn Difference Trace ...................................................5-110
Figure 5-38 RSO Dual-Trace Multi-Shorts.........................................................................5-110
Figure 5-39 RSO Difference Trace Multi-Shorts................................................................5-111
Figure 5-40 STD by Open Circuit .........................................................................................5-112
Figure 5-41 STD by Impedance ...........................................................................................5-113
Figure 5-42 C-Core 1...........................................................................................................5-114
Figure 5-43 C-Core 2...........................................................................................................5-115
Figure 5-44 Rotor Ground Split Voltage ............................................................................5-117
Figure 5-45 Rotor Ground Current Through Forging .........................................................5-118
Figure 5-46 Example of a Probability Distribution and Limit State Function..........................5-121
Figure 5-47 Basic Elements of a Probabilistic Analysis ........................................................5-122
Figure 5-48 Example of SPE Inspection Criteria Using Series of Probability of Failure
Curves..........................................................................................................................5-123
Figure 5-49 Ratio of Actual Crack Sizes to Measured Crack Sizes ......................................5-125
Figure 6-1 Oil Flushing Piping................................................................................................6-10
Figure 7-1 Ten-Year Record of Rotor Bowing ......................................................................... 7-4
Figure 7-2 Exaggerated Rotor Motion for the First Three Field Critical Speeds....................... 7-8
Figure 7-3 Low-Speed Portable Balance Machine .................................................................. 7-9
Figure 7-4 Various Standards for Residual Unbalance...........................................................7-16
Figure 7-5 Offset Modification to a Shell Bore........................................................................7-17
Figure 7-6 Access to Balance Grooves ..................................................................................7-18
Figure 7-7 Split-Weight Dovetail Weight.................................................................................7-21
Figure D-1 Foreign Material Exclusion Flowchart .................................................................. D-12
Figure D-2 Example of an FME Plan Document.................................................................... D-18
Figure D-3 Example of an FME Boundary Sign..................................................................... D-19
Figure D-4 Example of an FME Boundary Sign..................................................................... D-20

xxiv
Figure D-5 Examples of FME Boundaries and Entry Locations............................................. D-21
Figure D-6 Example of an Individual Entry Log ..................................................................... D-24
Figure D-7 Example of a Long-Term Placement Log............................................................. D-25
Figure D-8 Example of Lanyard Use ..................................................................................... D-36

xxv
LIST OF TABLES
Table 1-1 Breakdown of Condition Assessment ...................................................................... 1-8
Table 1-2 Critical Components Identified in Assessment Procedure ......................................1-10
Table 1-3 Cause Codes Associated with Critical Components Found in the Assessment
Procedure.......................................................................................................................1-12
Table 1-4 Effect of Component Condition Changes on Fossil Cycle Performance
Parameters (at Valve Wide Open Operation) .................................................................1-22
Table 1-5 Guidance for Interpreting Turbine Cycle Steam Flow and Unit Load Changes .......1-23
Table 1-6 Effect of Leakage to the Condenser on Heat Rate and Load..................................1-24
Table 1-7 Example of Overall Unit Condition Assessment .....................................................1-50
Table 2-1 Index to Turbine Outage Report: Appendices B and C............................................ 2-2
Table 2-2 Checklist of Pre-Outage Activities ........................................................................... 2-8
Table 2-3 Recommended Process Instruction Sheet and Detailed Work Package
Information .....................................................................................................................2-10
Table 2-4 Recommended Information for Parts and Part Use Databases ..............................2-11
Table 2-5 Post-Outage Activities............................................................................................2-15
Table 2-6 Recommended Parts Purchase Document Information..........................................2-19
Table 2-7 Recommended Diaphragm Repair Purchase Document Information......................2-20
Table 2-8 Recommended Information for Bucket Replacement or Repair ..............................2-29
Table 2-9 Geometry and Tolerances Required to Support a Repair Procedure......................2-31
Table 2-10 Classification of Generator Components ..............................................................2-33
Table 2-11 Generator Tests and When They May Be Performed...........................................2-34
Table 2-12 Parts and Consumables Used to Support Routine Work ......................................2-38
Table 2-13 Examples of Specialized Sources for Locating Vendors and Supplies .................2-42
Table 2-14 Selected Activities and Estimated Lead Times.....................................................2-43
Table 2-15 Basic Elements of a Scaffolding Plan...................................................................2-45
Table 2-16 Typical Locations Where Asbestos Is Found Around a Turbine............................2-49
Table 2-17 Items Recommended in an Asbestos Abatement Program ..................................2-50
Table 2-18 Alternative Lifting Devices for Turbine-Generator Components............................2-55
Table 2-19 List of NDE Equipment Used to Support a Turbine-Generator Outage.................2-63
Table 2-20 Areas of a Turbine-Generator to Be Protected During Disassembly.....................2-71
Table 2-21 Areas of a Turbine-Generator That Should Be Blocked........................................2-72
Table 2-22 Example of FME Measures During Turbine Disassembly and Reassembly..........2-75

xxvi
Table 2-23 List of Recommended Training Topics .................................................................2-86
Table 2-24 Typical Consumables Required for an Outage.....................................................2-88
Table 3-1 Steps Typically Involved with the Shutdown of a Turbine-Generator ....................... 3-4
Table 4-1 Checklist for Preparing a Lay-Down Plan................................................................ 4-2
Table 4-2 Activities Required to Support a Generator Field Rewind........................................ 4-7
Table 4-3 Tooling and Support for Turbine Deck Lay-Down Plan...........................................4-10
Table 4-5 Comparison of Accuracy Between Different Preload Methods [14].........................4-26
Table 4-7 Outage Fastener Usage Record.............................................................................4-34
Table 4-8 Checks to Determine Compatibility Between Original and Replacement Rotors.....4-41
Table 5-1 NDE Inspection Methods Used on Different Turbine-Generator Elements .............. 5-4
Table 5-2 Visual Inspection Methods Used on Different Generator Elements ......................... 5-8
Table 5-3 Sizing and Mapping Constraints Associated with NDE...........................................5-18
Table 5-4 Cleaning Processes Used for Coated and Non-Coated Components.....................5-19
Table 5-5 Support Information Required to Interpret UT Data ................................................5-23
Table 5-6 Coupling Inspections Disassembly and Reassembly...........................................5-29
Table 5-7 Recommended Action for Bearing Damage Typically Found at Inspection.............5-33
Table 5-8 Recommended Pre-Outage Preparations for Bearings...........................................5-34
Table 5-9 Separate Areas That Form a Stationary System....................................................5-35
Table 5-10 Recommended Action for Diaphragm Damage Typically Found at Inspection......5-37
Table 5-11 Blade Damage Typically Found at Inspection.......................................................5-42
Table 5-12 Typical Seal Design Clearances with Field Tolerances ........................................5-49
Table 5-13 Casing Repair Issues ...........................................................................................5-56
Table 5-14 Combined Cooling Designs with Retaining Rings.................................................5-57
Table 5-15 Alternative Processes for Grinding Collector Rings ..............................................5-63
Table 5-16 Generator Electrical Tests....................................................................................5-66
Table 5-17 Capabilities of LAI vs. Conventional Inspections ..................................................5-68
Table 5-18 Summary of Advantages and Disadvantages of LAIs...........................................5-69
Table 6-1 Recommended Cleanliness Criteria........................................................................ 6-7
Table 7-1 Specifications for an On-Line Active Balancing System..........................................7-12
Table 7-2 Sources for Equipment and Rotor Balancing Standards.........................................7-15
Table 8-1 Recommended Outline for a Startup Document ...................................................... 8-2
Table 9-1 Recommended Information to Be Collected After the Outage Is Complete.............. 9-3
Table 9-2 Examples of Post-Outage Engineering Reporting ................................................... 9-5
Table 9-3 Uses for Engineering Information Obtained in the Outage....................................... 9-8

1-1
1
TURBINE-GENERATOR CONDITION ASSESSMENT
IN SERVICE
In order to justify the extension or reduction of time between overhauls of turbine-generator
components, a systematic procedure is presented in this section to guide in the gathering and
evaluation of information that, in turn, may be used to assess the turbine-generators condition
since the last major overhaul. The assessment procedure in this section deals primarily with the
information that can be obtained and evaluated while a unit is operating. The condition
assessment presented later in Section 5 of this volume treats the information and processes that
are recommended for when the unit is off-line and components or systems are available for
detailed inspection and testing.
1.1 Overview
The purpose of this steam turbine-generator condition assessment is to:
Track and monitor the turbine-generators condition since its last overhaul
Assemble relevant information from multiple sources (interviews and reviews of actual
maintenance or operating information)
Offer a basis for assessing the collected results in term of recommendations for future work
scope and schedule
This procedure and method of reporting is not to be confused with a system of artificial
intelligence or decision-making software. This is a step-by-step process to be undertaken by an
assigned team of experts and specialists. It is supported with a series of generic formats (data
sheets) to guide in the collection of information for the purpose of making an informed,
documented determination of when work on a specific system or component of a unit should be
performed.
This type of assessment is to be conducted by appropriate technical personnel and specialists
acting as a group, with support provided by others within the specific plant or utility as
necessary. Personnel likely to be involved in the process include:
Those who are familiar with plant operations, such as a unit engineer
Those who are responsible for unit operations and conducting various tests on the equipment
Staff or plant personnel responsible for unit performance monitoring
Staff personnel responsible for unit vibration monitoring

Turbine-Generator Condition Assessment In Service
1-2
Plant electrical and mechanical personnel responsible for performing preventive maintenance
(PM) or predictive maintenance (PdM) on the various equipment
Staff chemistry personnel responsible for maintenance of steam and water purity within
specified limits
Input and insight will be required from all the above individuals in order to obtain the best
possible assessment of the turbine-generators current condition.
It is important to note that this procedure is designed so that, when each evaluation process is
complete, there is only one of three possible outcomes for the systems, sections or components
involved:
The current condition is rated as excellent, and the inspection interval should be extended.
The current condition is rated as acceptable, and the inspection interval can be maintained.
The current condition has significantly or drastically changed, and the inspection interval
should be reduced on various components or systems.
For each of these possibilities, only three types of recommendations are allowed in terms of
when the unit should be taken off-line so that corrective action can be implemented:
Immediate This recommends that a weekend shutdown be scheduled to correct a
potentially serious problem.
Intermediate This recommends that the maintenance be deferred until the next scheduled
outage.
Long term This recommends that major maintenance be performed but not until the next
scheduled overhaul, based on the most current evaluated condition.
These recommendations are highlighted in the summary page of the condition assessment (Data
Sheet #17) report by the use of color coding where the following definitions are applied:
Green. There are no perceived problems, and the system or component is expected to
perform reliably until the next assessment.
Blue. No specific immediate or intermediate action is considered necessary, but the issue is
significant enough to be monitored.
Yellow. Work is required at the next convenient outage; otherwise, a potential problem will
develop that could become serious (threaten a forced shut-down) if not corrected.
Red. A specific component or system needs immediate attention. Risk of a component or
system failure is considered high, and such a failure would cause loss of the unit for an
extended time.
If the condition is rated as good or excellent, the item would be color-coded as green, and the
summary report should recommend that the scheduled maintenance for these systems or
components be long term, with the options to extend, maintain, or shorten the present intervals
based on the further details gathered in the assessment.

1-3
In the case of the other two possible outcomes (immediate or intermediate) where some
condition degradation is identified, the three possible colors allow the degradation to be further
monitored (blue), treated as soon as conveniently possible (yellow), or immediately (red). As a
general rule of thumb, unless an unexpected event of drastic proportions has suddenly occurred,
the yellow or red rating would be based on more than just an anomaly noted in some indicator or
sensor. An issue or problem flagged with a yellow or red code on the summary sheet should have
the suspected root cause(s) identified and the appropriate action specified, based on this
diagnosis. In other words, every issue associated with degradation of a system or component
does not demand a shutdown of the unit. This ultimate action can be deferred until the condition
is more precisely defined if the trending of the key criteria or parameters that identified the
problem or issue indicates that time permits additional study.
This decision of course, must be balanced against the system or component that is involved and
the potential risk if a sudden unexpected breakdown of the system should occur. For example,
evidence of either a balancing or a misalignment problem might be studied at greater length to
identify which of the two is most likely, and the appropriate corrective resources could be
planned in the most effective manner. However, the threat raised by a high particle count
observed in the bearing lubricating oil system is more immediate and not worth the risk to the
bearings and/or the turbine-generator system.
A summary form, Data Sheet #17 (see Figure 1-1), is used to document the condition
assessment based on information gathered on Data Sheets #116. These data sheets are
provided in Appendix A.

Figure 1-1
Example of the Form Used to Rate the Final Condition of the Turbine-Generator
The intention for a limited number of outcomes and the use of color codes is to force the
assessment to a conclusion and to summarize the results into recommendations that are easy to
present to and use by management. Given that two of the three possible recommendations from
the assessment could require the unit to come off-line earlier than originally planned, the

1-4
financial consequences of such a decision will invariably be a factor. Therefore, for a condition
assessment to be effective, it must offer tangible recommendations, not simply provide a
chronicle of assembled data.
In this regard, it should be recognized that the assessment approach and method offered here is
based on the best combined judgment of the personnel who are responsible for the operation and
maintenance of the turbine-generator units. These judgments and recommendations are to be
supported by the indicators, trends, known problems, and issues that have been collected specific
to the unit since the last overhaul or conditions that may have occurred at some time in the past.
In certain cases, particularly where the outcome indicates a red condition (where immediate
attention is recommended), the human judgment of this in-service procedure can then be further
supported by an analytical risk assessment in which all of the pertinent facts are considered. This
supplemental assessment is most likely to involve issues associated with the rotating
components, particularly those whose catastrophic failure would seriously harm or damage the
unit, and not just shut it down. Examples where such analytical assessments might be appropriate
for high-pressure (HP) and intermediate-pressure (IP) rotors include the potential for creep
failures, solid-particle erosion (SPE), high-cycle fatigue (HCF), and erosion, typically for the
first HP and first reheat stages. For LP rotors, the probability for stress corrosion cracking (SCC),
HCF, low-cycle fatigue (LCF), water droplet erosion, stall/flutter, and corrosion fatigue would
most often focus on the last stages of the LP turbine wheel attachments and blades.
It is at this point where the responsibility of the condition assessment ends, and the work
remaining transitions into a task of life cycle management (LCM). EPRI has produced a series of
Life Cycle Management Planning Sourcebooks, each of which contains a compilation of industry
experience, information, and data on aging, degradation, and historical performance for specific
types of systems and components. These are potentially useful as references to complement and
compare with the information assembled during this machine-specific condition assessment.
The EPRI report name, number, and date of publication for Volumes 110 of the LCM Planning
Sourcebooks are as follows
Report Name Report # Report Date
Volume 1: Instrument Air Systems 1006609 December 2001
Volume 2: Buried Large-Diameter Piping 1006616 May 2002
Volume 3: Main Condenser 1003651 March 2003
Volume 4: Large Power Transformers 1007422 March 2003
Volume 5: Main Generator 1007423 July 2003
Volume 6: Feedwater Heater Controls 1007425 March 2003
Volume 7: Low Voltage Electrical Distribution Systems 1007426 February 2003
Volume 8: Main Turbine 1009071 January 2004
Volume 9: Electrohydraulic Controls 1009072 September 2003
Volume 10: Feedwater Heaters 1009073 December 2003

1-5
1.2 Procedure and Objectives
The principal objectives for applying the approach discussed in this section to perform an in-
service condition assessment can be summarized as follows:
1. To assess whether the unit may be able to operate successfully until the next major planned
overhaul. This recommendation is qualified based on the limits of the evaluation. The
objective is to provide a basis for why an unscheduled outage or an extension of a major
overhaul interval is recommended. The major limitation to the quality of this condition
assessment is the inability to evaluate the condition of internal steam path stationary and
rotating parts by means of direct visual inspection. However, by looking at and trending
performance data and startup vibration, by performing visual and limited NDE in the exhaust
ends of the turbine, and by reviewing bearing metal temperatures and other turbine
supervisory instrumentation (TSI) data, it should be possible to obtain a reasonable picture of
the internal health of the turbine-generator.
2. To determine what maintenance work needs to be performed on the unit during a weekend
shutdown or upcoming future outages. The objective is to reduce the potential of a forced
outage prior to the next major planned unit overhaul.
3. To provide additional input for determining the risk of failure (P
f
) associated with extending
turbine-generator outage intervals. Analytical calculations can be performed using stress
(both dynamic and steady), material property variations, and operating data to analytically
predict blade failure probability due to SCC, HCF, LCF, SPE, erosion, and creep. The need
for such an analysis is dependent on the uncertainty of assigning failure probabilities to
certain turbine components and their value to the utility.
4. To provide a relative risk assessment of the individual turbine sections and systems of a
specific plant. When a formal system is in place, it becomes possible to compare the risk
assessment to other units within the fleet.
Three tasks are to be accomplished in the process of performing this level of condition
assessment:
Completion of evaluation forms (found in Appendix A). These should be kept as records and
used as the basis to regularly assess, monitor, and trend unit condition change over time.
Development of recommendations for work to be performed on a short-term, intermediate-
term, or long-term basis. These are done for each system and component and itemized on the
summary sheet.
Development of recommendations for extending or shortening the time interval for the next
planned major outage with justification as to why this work is required.
The overall unit condition evaluation of the turbine-generator and its systems will require input
from technical support personnel involved in turbine-generator and plant maintenance and from
operations and performance personnel. This information will be used to complete all attachments
and to give an overall risk assessment of the turbine components and systems.

1-6
As noted previously, and in addition to the above recommendations, each component should be
assessed using a color scheme that makes it easier for management to review and focus on the
most critical issues or problems with the machine.
1.3 Planning a Steam Turbine-Generator Condition Assessment
Before proceeding with obtaining the data discussed in this procedure, the following four basic
concepts/actions should be clearly communicated to the condition assessment team:
Responsibility. The organization responsible for planning, scheduling, budgeting,
coordinating, and performing the condition assessment of turbine-generators within the
system should be clearly identified.
Resources. The personnel resources required to coordinate and perform condition
assessment of turbine-generators should be identified. Additional resources at a specific
station/site for which the assessment is being conducted and the time required of these
resources should also be identified. This is necessary to ensure timely completion of data
sheets and the turbine-generator unit condition assessment.
Budget and Schedules. The group responsible for developing a long-range and/or annual
schedule must be identified. This plan and schedule should identify what turbine-generator
units will require an assessment with a specified completion date. Included in this should be a
budgetary estimate of all costs associated with performing the assessment. Estimated costs of
different corrective actions may be found in the previously referenced LCM sourcebook,
Main Turbine, 1009071, first published in January 2004.
Frequency. The frequency for conducting a condition assessment on a turbine-generator
should be identified. In general, the following guidelines are recommended:
A baseline assessment should be conducted as soon as practical after a major overhaul to
provide a benchmark for subsequent comparison and evaluation.
A second assessment should be considered at mid-cycle relative to the next scheduled
major inspection. For example, if a unit is on a 10-year inspection interval, the next
condition assessment should be conducted after five years of operation.
The frequency of the inspection interval after this should depend upon the findings of the
first condition assessment.
If the second condition assessment is satisfactory, the last assessment should be
conducted one to two years in advance of the scheduled overhaul.
Contingent upon its findings, the final assessment may show that the planned overhaul can be
postponed or must be performed earlier than planned. An interval extension may be supported by
calculated failure probabilities based on analytical calculations.

1-7
1.4 Documentation of Condition Assessment
The final report of the turbine-generator condition assessment (along with any additional
information/documentation) should be filed at the specific plant where the assessment was
performed and at the utility general office. A series of recommended forms are provided in
Appendix A: Data Sheets #1 through #17. Note that these forms are meant to be both
comprehensive and generic in nature. Not all are required to be completed for many units. Only
the most relevant information should be incorporated in the final condition assessment report
(Data Sheet #17).
1.5 Condition Assessment Procedure
The assessment begins with a systematic collection of information that is typically available
while a unit is in service. The data sheets in Appendix A have been organized in a manner and
sequence to provide a natural framework for this process and a comprehensive report that can be
updated at each successive assessment interval.
The 17 separate data sheets are listed in Table 1-1. Generally, each series of data sheets consists
of the three same basic parts:
The first part is identified as an audit. This sheet provides a summary of relevant available
data collected from the system as a whole or from individual sections.
The second sheet supplements the first by identifying key questions that are to be answered
by means of an interview with the specialist, engineer, or operator directly responsible for
maintaining and monitoring the system.
The third sheet uses a consistent format to summarize the findings drawn from the audit and
interview. The perceived risk and considered need for action are both identified.
Four of the series are distinct from the others in that they form the minimum of information that
a condition assessment would always include:
Series #1 provides an overall review and assessment of the maintenance history for the unit,
including a record of any upgrades made to replace original systems.
Series #15 is a checklist of 69 out-of-limit indicators. These highlight the myriad of
unexpected problems or issues that are common to large steam turbine-generators.
Series #16 is a summary of the current long-range maintenance plans for the individual
systems, sections, and components that are contained within the unit.
Series #17 is the consequence of the information obtained and reviewed in the preceding
series of documents. It provides a one-page synopsis that lists the components/systems and
then ranks their present condition. It is the last form completed, but it should be used as the
first page of the report, with the subsequent sheets attached.

1-8
Table 1-1
Breakdown of Condition Assessment
Series System or Component Data Assembled and Reviewed
1 Maintenance History Summary Record of modifications and upgrades
2 Turbine-Generator Vibration Readings at minimum-maximum load, criticals
3 Bearing Metal and Oil Temperatures Readings at minimum-maximum load
4 Section Performance Parameters Readings at full load, valves wide open
5 Start-Up Operation Record of starts, trips, service hours
6 Steam Purity Frequency of tests, criteria, out-of-spec events
7 Lubricating Oil and EHC Analysis Particle counts, presence of contaminates
8 Pump Start Tests Frequency of tests, pressures, out-of-spec events
9 Valve Tightness Tests Frequency of tests, criteria, sticking events
10 Turbine Trips and Tests Record of trips, results, consequences
11 Turbine Monitoring Instrumentation Readings at minimum-maximum load, calibrations
12 Generator-Exciter Condition Readings, criteria, test results
13 Auxiliary System Operation Readings, criteria, test results
14 Visual Inspection Results HP, IP, LP inlets and exhausts
15 Checklist of Out-of-Limit Events Record of unit upsets, actions, and consequences
16 Current Maintenance Plan Record of inspections: last, next, frequency
17 Overall Condition Assessment Summary with recommended actions
As noted, it may not be necessary to complete Data Sheets #2 through #14 for every unit. The
extent to which the assessment is performed is at the discretion of the owners and operators.
The checklist of indicators provides a snapshot to identify warnings of problems that should also
be subsequently covered in the more detailed evaluation of a specific system or component.
However, these warnings only highlight a potential problem and do not provide the additional
detail that an audit or interview is meant to supply as a basis for estimating the risk of a failure
and the type of action that is needed.
Data Sheet #17 is essentially a digest of the critical systems and components, itemized for the
main steam turbine in Data Sheet #16. It principally focuses on the fundamental issues or
problems identified in the assessment, although it should include an assessment of certain
systems whose health is critical to the reliable operation of the turbine-generator. In other words,
it is just as valid to report that the conditions of these key systems are presently considered good,
as it is to highlight the potential or immediate problems. As a general rule, the summary report
should not exceed a single page.

1-9
The next 14 subsections of this section present a system-by-system breakdown of the checks,
inspections, tests, etc., that are recommended on particular systems and components and some
guidance in how these would be used to evaluate the operating health of the machine. The sub-
sections are in the sequence of the data sheets previously shown in Table 1-1.
Each set (series) of data sheets is referenced to a specific plant and unit number, with the
following generic information included throughout the package of information that is finally
assembled into a report:
Turbine, generator, and exciter original equipment manufacturer (OEM)
Unit maximum dependable capacity (MDC) and unit design rating
Date the unit went into commercial operation and date the unit was last inspected
1.5.1 Turbine-Generator History, Upgrades, and Major Forced Outage Events
After the proper planning and organizational measures have been finalized, a condition
assessment may be initiated. The process starts by using Data Sheet #1 to prepare a detailed list
of past maintenance performed on the specific turbine, generator, or auxiliary system. The
purpose for completing this form is to have a concise and up-to-date record on the components
and systems that make up the particular turbine-generator under assessment. This step in the
assessment is meant to provide a historical perspective, which in turn is used to weigh the
importance of issues or anomalies that are identified for certain systems or parts. It identifies
what types of problems have been reported in the past, whether a problem appears to be chronic,
and if that problem has been eliminated.
Part 1(a) of this set of data sheets assembles a baseline of information that reflects the date that
critical components of the unit were inspected. Key recommendations made as a consequence of
these inspections are also identified, and whether the action taken was considered to be
addressing a chronic problem is noted.
To assist in defining what is considered to be a critical component, in the aforementioned
EPRI Life Cycle Management Sourcebooks, the critical components of the main turbine,
generator, controls, and support systems were organized by their function. The most prominent
components in the assessment procedure are shown in Table 1-2. These components form an
integrated system within the overall unit and are subject to a condition assessment as opposed to
an assessment of single parts (nuts, bolts, tenons, etc.) that make up a component.

1-10
Table 1-2
Critical Components Identified in Assessment Procedure
Classification Critical Components (If Present)
1 Pressure Boundaries HP/LP Outer Casing, HP/IP Inner Casing
2 Piping Interconnecting, Cross-Over, Cross-Under
3 Nozzles Impulse and Reaction
4 Turbine Rotor Sections HP, IP, and LP Rotors; Disks and Blades
5 Packing and Seals Interstage Packing, Shaft End Seals, Oil Seals
6 Coupling and Bearings Bolts, Shells, Journals, Pads
7 Front Standard Assemblies Main Oil Pump, Speed Sensors, Trip Systems, PMG
8 Essential Instrumentation Vibration, Temperature, Expansion, Speed
9 Generator and Exciter Stator, Rotor, Windings, Hydrogen Seals, Coolers
10 Controls Valves, Governors, Trips, Meters, Regulators
11 Lubrication Bearing Oil System, EHC System
Part 1(b) of this set of data sheets provides a record of any modifications or upgrades that were
made to improve the units performance or reliability over its history of operation. In making this
evaluation, it should be noted that to improve the reliability of the component does not
necessarily require a design modification. For example, a replacement in-kind with a new
component would reflect a condition whereby the accumulated damage to the original material is
eliminated. A replacement re-sets the aging clock for the time-dependent mechanisms that
caused the original material properties of the component or system to deteriorate.
Part 1(c) assembles a list of the significant forced outages that have occurred and the components
they affected (such as a blade failure, a bearing journal wipe, etc). If the root cause is suspected
or known, these should be described. Any specific documentation available should be referenced
or attached. When defining what type of information should be included in this section, a
significant forced outage event is one in which the unit was automatically removed from service
based on a turbine supervisory trip or was removed from service by operators in order to correct
a deficiency that could have seriously jeopardized the units operational reliability.
Part 1(d) concludes this review with an assessment of the potential risk for failure, based on the
past maintenance history. A judgment is required as to whether the forced outage events
identified on the prior sheets are likely to be isolated events or symptoms of a longer, chronic
problem. The judgment of potential risks is consistent with all the parts forming a condition
assessment and is reduced to three possibilities: high, medium, or low. Because this is dealing
with the maintenance history, the need to recommend action associated with each itemized
problem is not required. Instead, this is determined on a component-by-component basis based
on the most recent information made available through audit and interview.

1-11
As reflected on the data sheet, the maintenance history does not necessarily have to be limited to
any specific item, but it also should not be too detailed. In other words, when subsequent parts of
the evaluation identify specific issues, this summary provides a basis for deciding if this is a new
problem, a chronic problem, or a routine problem.
A new problem may indicate that a system or component is reaching the end of its useful life, or
it may reflect the consequence of an action taken during the last overhaul. A repeat or chronic
problem suggests that a more permanent solution is warranted, and the condition assessment may
need to account for the additional planning and time to find this solution, as well as the potential
risk if the problem worsens. A routine problem would be one that can be expected to require
action on a periodic basis. Trending the rate at which the systems or components condition
appears to deteriorate provides the basis to either shorten or lengthen the interval of inspection
and planned replacement.
When beginning an assessment, a search of available databases is recommended to assist the
condition assessment team in determining an initial list of historical issues that might be
considered for further scrutiny in a unit-specific assessment. For example, details such as those
compiled by the North American Electricity Reliability Councils Generator Availability Data
System (NERC-GADS) can provide a broad profile of what the plant has officially reported on
the unit over time. So as not to be overwhelmed by this raw data, the user should seek
information only on a specific unit and focus on entries that are classified as unplanned events
involving required maintenance action. Events compiled within the NERC-GADS database are
organized and reported with cause codes. A partial list of cause codes associated with the main
turbine is shown in Table 1-3. A search made for a specific unit can produce a simple record like
that shown in Figure 1-2. This forms a starting point to build and cross check a historical record
of system or component maintenance. It can also be useful in identifying specific issues that
would be pursued in the interview part of the assessment.

1-12
Table 1-3
Cause Codes Associated with Critical Components Found in the Assessment Procedure
Critical
Components
NERC-Defined Cause Codes
Other Steam
Turbine-Generator
Problems (All
Components)
4499:
Other
Problems

Pressure
Boundaries, (HP/LP
Casing and Hoods)
4000:
HP Outer
Casing
4001:
HP Inner
Casing
4200:
LP Outer
Casing
4201:
LP Inner
Casing

Interconnecting and
Crossover Piping
4270:
Crossover
Piping
4279:
Miscellaneous
Turbine Piping

Nozzle Boxes 4009:
HP Nozzle
Bolting
4010:
HP Nozzle
Boxes
4209:
LP Nozzle
Bolting
4210:
LP
Nozzle
Boxes

HP Rotor Sections
(Disk, Blades,
Stationaries)
4011:
HP
Diaphragms
4012:
HP Buckets
Blades
4013:
HP
Diaphragm
Unit
4014:
HP
Bucket
Fouling
4015:
HP Wheels
or Spindles
4030:
HP Rotor
Shaft
4099:
Other HP
Problems
LP Rotor Sections,
(Disk, Blades,
Stationaries)
4211:
LP
Diaphragms
4212:
LP Buckets
Blades
4213:
LP Blade
Fouling
4215:
LP
Wheels -
Spindles
4230:
LP Rotor
Shaft
4250:
Other LP
Problems

Packing (Interstage
and Shaft End), Oil
Seals
4020:
HP Shaft
Seals
4021:
HP Dummy
Rings
4022:
HP Gland
Rings
4220:
LP Shaft
Seals
4221:
LP Dummy
Rings
4222:
LP Gland
Rings
4430:
Gland Seal
System
Bearings and
Couplings
4040:
HP
Bearings
4240:
LP Bearings

Front Standard
Bearing Pedestal
Instrumentation and
Associated TSI
4280:
Lube Oil
Pumps
4300:
Turbine
Supervisory
System
4309:
Other
Turbine I & C
Problems

Essential Condition
Monitoring (TSI)
Instrumentation
Data
4420:
Turbine
Vibration

Major Turbine
Overhaul >720 hrs
(All Components)
4400
Major
Overhaul

1-13
Caution should be exercised in analyzing raw entries in the NERC-GADS data. Scrutiny must be
applied to ensure that events are categorized and counted correctly. This principally involves (a)
reviewing the cause code component identification and (b) consolidating multiple events.
Specific cause codes tend to be assigned subjectively. The same problem can be associated to
causes that differ from plant to plant. Some plants use the Turbine Vibration and Other Steam
Turbine Problems categories as a catchall. A review of each entry should be made to ensure that
it was assigned to the proper component (when details on the entry make this possible).
Multiple events should be consolidated into one when the records indicate that they were actually
associated with a single, larger event. The most common example of this circumstance is when
several attempts were required to return a unit on-line, with each being logged as a separate entry
associated with turbine vibration. In such instances, the multiple GADS entries dealing with
the same issue (often occurring within a period of hours or minutes) should be treated as a single
occurrence for that type of event, and the individual hours for the multiple entries consolidated
into a total for the single event. This step prevents overestimation of the frequency of reports
made for the specific component.

Figure 1-2
Example of NERC-GAD List of Maintenance Outage Events for a Typical Unit

1-14
Beyond the previously listed LCM sourcebooks, additional research published by EPRI that is
associated with historical experience on component or system reliability, upgrades, and major
forced outage events related to turbine-generators is as follows (listed by year of publication):
Survey of Steam Turbine Blade Failures, Project 1856-1, EPRI, Palo Alto, CA: 1985. CS-
3891.
Condition Assessment Guidelines for Fossil Fuel Power Plant Components, EPRI, Palo Alto
CA: 1990. GS 6724.
Improving Maintenance Effectiveness Guidelines: An Evaluation of Plant Preventative and
Prediction Maintenance Activities, EPRI, Palo Alto, CA: 1996. TR-107042.
Main Turbine Performance Upgrade Guideline, EPRI, Palo Alto, CA: 1997.
TR-106230.
Low Pressure Rotor Rim Attachment Cracking Survey of Utility Experience, EPRI, Palo Alto,
CA: 1997. TR-107088.
Reliability Assessment of North American Steam Turbines, EPRI, Palo Alto CA: 2002.
1006952.
Component Failure Database: Version 2.0, EPRI, Palo Alto, CA: 2003. 1004863.
Predictive Maintenance Primer: Revision to NP-7205, EPRI, Palo Alto, CA: 2003. 1007350.
1.5.2 Turbine Vibration
The signature obtained from the turbine-generator bearing vibration instrumentation may reflect
a condition of misalignment or unbalance present within the system. Characteristics (frequency,
amplitude, and phase) are typically processed by an expert or specialist in vibration diagnostics.
For operators, vibration limits are set to prevent damage caused by exceeding the journal
clearances. The condition assessment of turbine vibration is intended to identify the root cause of
problems that may be indirectly reflected in the system vibration signature. When trended, the
vibration signatures can also provide a sense of whether the problem is stable or deteriorating
over time.
Data Sheet #2 (a) assembles a complete set of turbine-generator vibration amplitude and phase
angle data recorded from the unit at both full load and minimum load. Obtaining data on a unit
roll-up and roll-down is also strongly recommended. In addition, a frequency scan should be
recorded and attached to the respective data sheet at each bearing location. The specialist
providing these data should also be the individual who is responsible for tracking, trending, and
evaluating any significant data changes in comparison to readings taken at the last outage or to
the first set of benchmark data taken after the unit is returned to service.

1-15
On #2 (b), the data recorded in the audit is then analyzed by the vibration specialist through an
interview process. A series of questions are identified. These are designed to assist in soliciting
details and opinions that go beyond the data collected and summarized on the initial sheet.
Ultimately, the results from the audit and interview are summarized in the third sheet #2 (c),
where both the risk of failure (low, medium, high) and the need for action (immediate,
intermediate, long term) are identified relative to the turbine vibration.
To assist in the interpretation of data assembled from both the audit and the interview, typical
orbit plots showing symptoms of common problems registered in the vibration signature are
provided in Figure 1-4. A more detailed discussion on the symptoms and interpretation of
vibration measurements related to common turbine-generator balance and alignment problems
can be found in Volume 3 of these Guidelines, specifically the Balance Primer and the
Alignment Primer.
In terms of possible actions relating to turbine vibration, the most common issues likely to be
found in an assessment are:
Repeated balancing attempts are ineffective. This involves a condition where significant
changes in unit vibration have required numerous balance shots, but the running speed
vibration amplitude and phase angle at the shaft rotation frequency remain high or are still
not improved. For example, the failure to relieve the vibration problem may indicate that the
problem is instead with a coupling, or that unbalance in the rotor system is highly static
(where phase angles are in-line), indicated by the phase angles recorded at each bearing.
When considering recommendations, determine if a coupling has excessive run-out between
the coupling halves. If so, this condition will result in high vibration that cannot be improved
by balance shots. Coupling disassembly will be required to eliminate excessive run-out. A
large static unbalance in the rotor system may require shop balancing of one or more rotors to
correct this condition.
Significant changes are noted at harmonics of shaft speed. Vibration frequency scans should
identify any significant changes associated with one-half X, 2X, 3X, 4X, or 5X harmonics of
shaft rotational speed (where X represents rotor speed). For example, a frequency that is less
than one-half rotor running speed represents an oil whip instability if seen during unit
operation. There would also be a significant difference between the filter-out and filter-in
vibration amplitudes. A significant change in the 2X frequency response could be noted if a
unit has a large peripheral crack (with orientation orthogonal to the shaft centerline). Such a
response would be seen in comparing a 2X scan before and after cooling and re-heating a
rotor by changing the main or reheat steam temperature by 5075F (1024C). A large
difference between filter-in and filter-out vibration typically signifies significant vibration at
other frequencies as noted above.
If a vibration problem is identified, it should be considered as serious and treated
immediately in order to prevent a potential catastrophic failure of the rotor during operation.
Vibration technical experts should be immediately contacted to further assess this problem
and for guidance as to possible unit shutdown.

1-16
A major change is noted when load is added. Major changes in rotor vibration amplitude and
phase angle that occur from minimum load to full load can be due to alignment problems on
the unit or other reasons (such as partial arc loading issues at minimum load). For example,
on some units the static and dynamic vector components may show significant changes in
amplitude and phase between minimum load and full load. A subsequent alignment check
may reveal significant rim and face misalignment of one rotor to another rotor.
A major vibration change is noted when passing through shaft critical speeds. Significant
vibration amplitude and phase angle changes at rotor critical speeds could be caused by rotor
bowing. Such bowing can be due to operation at high temperature over a long time period or
due to rubs in the steam packing or elsewhere within the rotor system. This would typically
be seen in the HP or IP turbines.
Sudden step increases in vibration are measured at the journals. Large, sudden step increases
in journal vibration often indicate a loss of rotating blade material. Such changes generally
require immediate inspection to assess damage and determine other corrective actions that
may be required.
As a rule, progressive changes in measured vibration over extended periods of time reflect
degradation due to wear of the bearings, settling of the foundation, permanent rotor bowing, or
the cumulative effect of individual section overhauls that eventually require a major correction.
A condition assessment should seek to determine the point in time when a major unit
realignment would be worthwhile to restore the unit to its originally aligned condition. An
interview of the operators can aid in determining whether unit vibration problems have been
chronic, are getting worse, or have only recently started.
After multiple rotor overhauls, possible settling of the bearing foundation, and/or thermal
distortion of stationary components, the unit will require extensive alignment, This will establish
the radial position of the rotor with respect to stationary components and to re-establish the
cantenary position of the bearings to the initial cantenary line. If a system becomes badly
misaligned, it may become impossible to find a reasonable alignment solution without a
complete disassembly of the unit to perform a tops-on and tops-off alignment to correct the
problem.
Pronounced step changes in vibration typically signify a situation that requires immediate
concern and attention. These steps changes reflect a loss of noticeable rotating mass, often
caused when portions of a rotating blade such as a tip or cover are lost. This indication is
significant in that it may represent an early warning of the progressive deterioration of the
structural system as a prelude to a more catastrophic failure. For example, if the blade is
designed to have its natural frequencies fall within certain prescribed operating bands; the loss of
part of a cover band may shift one of the fundamental frequencies into a condition of resonance.
If a large blade fails at the platform or root, the loss of mass can be sufficient to cause an
unbalance that will cause extensive damage to the entire machine. Such cases have been recently
documented.

1-17

Figure A shows the orbit of a shaft with several concurrent whirls
at different frequencies taken from unfiltered vibration. Figure B
shows the same plot at synchronous speed where
nonsynchronous frequencies have been filtered out, showing the
unbalance whirl orbit.

Stiffness affects the shape of the orbit as noted
by Figures CE. Identical bearing stiffness
gives a circular orbit, dissimilar stiffness gives
an elliptical orbit, and cross coupling of
stiffness in vertical and horizontal direction
gives a rotated elliptical orbit.
Misalignment can be indicated as shown in
Figures FH. Note that the orbit is highly
elliptical in F, indicating poor alignment. In
Figure G the orbit for two bearings on each
side of a coupling are banana-shaped,
indicating severe misalignment. In Figure H the
misalignment is also severe and suggests
backward precession.
Fluid whirl, a subsynchronous fluid instability, occurs within the range of 3048%
of machine operating speed. Figure I shows precession of vibration in the same
direction as shaft rotation, displaying a circular orbit and two key-phasor dots. If
the dots slowly rotate against shaft rotation, the subsynchronous frequency is less
than 50% of shaft speed; if the two dots remain stationary, the frequency is
exactly 50% of shaft speed.
Fluid whip is a subsynchronous excitation at the first critical speed of a rotor that
operates far above twice first critical speed and has vibration amplitudes
equivalent to bearing clearance. The orbit for this is shown in Figure J. Note the
multiple key-phasor dots that this excitation produces.
Rubs are a typical problem seen on steam turbines and are generally at 1X
frequency for units that operate at less than twice first critical speed. If a rotor
operates well above first critical speed, frequencies generated would be at 1X and
1/2X frequencies. Figure K shows a rub in a unit whose speed is well above first
critical speed frequency and has a predominant 1/2X frequency.
Figure 1-3
Typical Orbits Showing Different Problems

1-18
In addition to the information referenced in Volume 3 of these guidelines, previous research
published by EPRI related to turbine-generator vibration is as follows (listed by year of
publication):
Periodic Vibration Monitoring: Utility Experience, EPRI, Palo Alto CA: 1987. CS-5517
Symposium Proceedings: Rotating Machinery Dynamics, Bearings and Seals, EPRI, Palo
Alto, CA: 1988. CS-5858.
Applying Vibration Monitoring, EPRI, Palo Alto CA: 1991. NP-6340.
Shaft Alignment Guide, EPRI, Palo Alto CA: 1999. TR-112449.
Technology Development for Shaft Crack Detection in Rotating Equipment Using Torsional
Vibration, EPRI, Palo Alto CA: 2003. 1009060.
1.5.3 Bearing Metal and Oil Temperatures
Pressure-lubricated journal-type bearings support the rotor shaft elements at both ends. A thin oil
wedge that is created by rotation within the stationary pads supports the shaft. Maintaining the
proper thickness of this oil wedge is critical to preventing bearing vibration due to oil film
instabilities. Since steam pressure differential across most turbine stages produces a net thrust
along the shaft, the thrust bearing provides a reaction force to this differential and limits the
rotors axial position to maintain proper axial clearances between the stationary and moving
elements. Loss of lubrication, oil temperature excursions, or contamination of the lubricating oil
can result in serious damage to the bearings. This step of the condition assessment is meant to
ensure that no unusual loading condition is occurring at the rotor journals or bearings.
As part of the assessment, bearing metal, oil inlet, and oil outlet temperatures should be recorded
at maximum and minimum load and recorded as recommended in Data Sheet #3(a). Recording
these data should also be considered throughout the load range. As in the previous Data Sheet,
#3(b) identifies a list of questions that should be answered as part of the specialist interview. The
series concludes with Data Sheet #3(c) and the assessment of risk and need for action relative to
this system or component.
The most common issues likely to be found in an assessment are:
Pronounced changes in metal temperature since the last evaluation which can be an
indication of alignment changes or bearing wipes. Both conditions generally represent a high
risk to the overall system. As with a step change in vibration, they should be taken seriously
and corrected promptly.
Sudden spikes in bearing metal temperature may indicate that a bearing may have actually
wiped. If a sudden metal temperature change has occurred, this can mean that other bearings
are now more heavily loaded. Their journal radial position may have changed, meaning that
the rotor may now be running close to a rub condition that could take the unit off-line and
potentially damage rotating and stationary components.

1-19
It should be noted that bearing vibration amplitude or metal temperature changes could be
observed on some units due to valve arc loading. For these units, this may be normal. It should
be considered an abnormal condition in the assessment only if this is the first time it has been
observed.
Actions that may be required to correct a bearing problem can include checking the rotor radial
position to either oil or gland bores along with the disassembly of couplings and realigning the
turbine depending on the radial position found. Such work can be easily accomplished during a
limited outage if planned sufficiently in advance.
A partial list of research published by EPRI related to aspects of turbine-generator bearing
operation is listed as follows (by year of publication):
Guidelines for Maintaining Steam Turbine Lubrication Systems, EPRI, Palo Alto CA: 1986.
CS-4555.
Manual of Bearing Failures and Repair in Power Plant Rotating Equipment, EPRI, Palo
Alto CA: 1991. GS-7352.
Bearing Troubleshooting Advisor, Version 2.0, EPRI, Palo Alto CA: 1994. AP-100531-R1.
Bearing Technology Topics: Various Technical Papers, Volumes 1 and 2, EPRI, Palo Alto
CA: 1999. TR-113059-V1 and V2.
1.5.4 Thermal Performance
The state-of-the-art methodology in axial steam turbine thermal design takes into account many
factors, including optimal stage-to-stage loading (enthalpy drop). Other design factors include:
Airfoil shapes used in nozzles, diaphragms, rotating blades/buckets (three-dimensional
designs being increasingly used)
End-wall shape (that is, the inner and outer boundaries of the flow passage
Blade/bucket shroud configuration
LP turbine stage wetness removal
Blade/bucket tie-wire losses
Interstage sealing
The dry internal efficiency of modern steam turbine sections ranges from the high 80s percentage
range to the low 90s percentage range. Wetness losses in both the HP (nuclear) and LP (nuclear
and fossil) sections of units reduce this efficiency somewhat, depending on the wetness level.
Individual stage efficiency, particularly in the superheated early stages of the LP turbine, can
exceed 90%. However, the overall multistage expansion is always less than the individual stage
efficiencies.

1-20
As part of the overall condition assessment, thermal performance degradation is used as an
indirect indicator for identifying problems that may be developing within the HP, IP, or LP
turbine steam paths that in some manner inhibit or disrupt the flow so that noticeable losses are
produced. These losses are reflected as a higher turbine cycle heat rate or loss of power output.
To facilitate the interpretation of performance-related test data, Tables 1-4 and 1-5 reflect
common changes in the condition of different components of the turbine steam path in terms of
their consequence on measurable performance cycle parameters. Table 1-6 provides general
guidance in terms of the impact on heat load due to various forms of steam leakage into the
condenser.
To make this assessment, the most current data should be gathered and recorded using Data
Sheet #4. Data assembled on 4 (a) should be trended at the same load point to further assess
performance degradation over time. Often, a key in the interpretation of overall performance data
is to isolate the cause within the respective section of the overall steam path.
Identifying the source of a suspected flow restriction can be approached in a systematic manner:
Steam extractions, reheat conditions, and moisture separators are logical cycle points that can
be used to identify turbine sections or plant systems that may be deteriorating.
The first HP (control) stage and last LP stage have a significant influence on the overall unit
performance. Although most turbines consist of a large number of individual stages, only the
first and last stages tend to be significantly influenced by changes in the flow rate. First stage
performance is primarily more sensitive to variations in load. The last stage is more sensitive
to variations in both load and backpressure.
Throttle flow factor is usually an indication of increased nozzle erosion. Trending this value
will give an indication of the rate of nozzle degradation that may be occurring for the specific
unit. Evaluation of other performance parameters may show other types of deterioration, such
as nozzle area closure or significant deposit formation on stationary and rotating blades.
Excessive erosion on the leading edge of a last stage blade may be an indication of high
feedwater levels in the neck heaters or of problems in the moisture removal system in the LP
section. If significant erosion is seen, such as 1/8" (3.18 mm) or greater on the leading edge
of a last stage blade since the last inspection, attention to feedwater heater controls should be
considered along with a detailed inspection of the LP section moisture removal system at the
next scheduled overhaul. If numerous tube leaks have occurred in these heaters, immediate
actions should be taken to eddy current inspect and plug suspect tubes. A long-term fix may
be to re-tube these feedwater heaters.
Operating at low loads and high backpressures can result in excessive moisture droplet
erosion in the last stage blades or the development of fatigue cracks due to a vibratory
condition referred to as flutter. This can occur as a result of increased cycling duty. In the
current utility financial operating environment, many units designed in the 1960s and 1970s
for base load operation are now being run to match peak consumption swings, sometimes on
a daily basis. When performing a condition assessment, changes to the condenser system or
operating pattern of the unit should be noted, and the condition of the LSB monitored for
these signs of distress during limited outages where the condition can be visually inspected.

1-21
Performance-related problems such as blade erosion or nozzle deterioration are generally not
catastrophic, unless a severe condition is allowed to persist. The incentive to address the thermal
performance issues is therefore typically based on the loss of efficiency produced by the
deterioration of the steam path. However, the location and extent of work that may be required to
restore a component should be seriously evaluated so that damage that would require only small
repairs is not allowed to escalate into a major scope of activities that compound the risk of an
extended outage due to unforeseen circumstances.
For example, erosion in the HP nozzles can normally be tracked by periodic visual inspection
with corrective actions planned for the next overhaul. Monitoring performance parameters such
as those identified in Tables 1-4 and 1-5 can assist in identifying consequences of such erosion.
However, if erosion cuts or erosion are allowed to become deep, the time required for repair will
be extended based the amount of weld repair required to correct the problem. The location of the
repair may also increase the level of risk assigned to a reliability issue. For example, extensive
erosion to the HP nozzle plates can then result in significant erosion to the HP first stage buckets.
Unintended removal of material from the buckets can make them more susceptible to resonant
vibration, particularly at certain valve points. It is this type of secondary consequence that should
always be considered when assessing the potential need and urgency to address an original
problem.
A partial list of research published by EPRI related to turbine-generator performance is as
follows (organized by year of publication):
Assessment of Supercritical Power Plant Performance, EPRI, Palo Alto CA: 1986. CS-4969.
Heat-Rate Improvement Guidelines for Existing Fossil Plants, EPRI, Palo Alto CA: 1986.
CS-4554
Fossil Unit Performance: 1965-1984, EPRI, Palo Alto CA: 1987. CS-5627.
Solid Particle Erosion Technology Assessment, EPRI, Palo Alto CA: 1994. TR-103552.
Thermal Performance Engineering Handbook, Volume 2: Advanced Concepts in Thermal
Performance, EPRI, Palo Alto CA: 1998. TR-107422-V2.
Turbine Steam Path Damage: Volumes 1 and 2, EPRI, Palo Alto CA: 1998. TR-108943.

1-22
Table 1-4
Effect of Component Condition Changes on Fossil Cycle Performance Parameters (at
Valve Wide Open Operation)
Condition Throttle
Low #/hr
P
T
P
1st
P
HRH
P
LP
H. P.
Efficiency
I. P.
Efficiency
Increase T
T
N. C. - -
Increase T
HRH
- N. C. - - -
Increase A
1st

(SPE) in HP
N. C. -
Increase A
HRH

(SPE) in IP
- N. C. - - -
Decrease A
1st
(Deposits and
Peening) in HP
N. C. -
Decrease A
HRH
(Deposits and
Peening) in IP
- N. C. - - -
Decrease A
2nd
(Deposits) in HP
N. C. -
Increase A
2nd
(Rubs) in HP
N. C. -
Decrease A
LP

(Deposits and
Damage) in LP
- N. C. - - - -
Note that every change in turbine condition results in a different three-key pressure pattern.

1-23
Table 1-5
Guidance for Interpreting Turbine Cycle Steam Flow and Unit Load Changes
Type Problem Timing Throttle Flow Section
Efficiency
Electrical
Load
SPE Gradual Increase Decrease (-HP

decrease greatest
at light load)
Increase or
essentially
constant
Deposits Gradual Decrease (may
increase after
shutdown)
Decrease (may
increase after
shutdown)
Decrease (may
increase after
shutdown)
Foreign Object
(Wrench, Bolts,
etc.)
Abrupt following
outages
Decrease Decrease Decrease
Peening (weld
bead)
Abrupt following
boiler repairs
Decrease Decrease Decrease
Mechanical Failure Abrupt anytime,
usually during
operation
Usually
decrease
Decrease Decrease
Water Induction Abrupt anytime
during operation
Slight increase Decrease Decrease
Vibration Abrupt, usually
most severe at first
startup
Steam Whirl Abrupt at first
startup
Internal Leakage
(Balance Hole
Plug)
Abrupt following
overhaul
Increase HP turbine
decrease
Decrease
Internal Leakage
(Inner Shell)
Gradual Slight increase Decrease Slight increase
Broken Valve Stem Abrupt Decrease Decrease Decrease

1-24
Table 1-6
Effect of Leakage to the Condenser on Heat Rate and Load
Effect of 1% Leakage to the Condenser on Fossil Reheat
Origin of 1% Leakage Flow On Heat Rate On Load
Throttle 0.83% 0.94%
HP Turbine Exhaust 0.53% 0.69%
Ahead of Intercept Valves 0.69% 0.56%
Crossover 0.44% 0.44%
Rules of Thumb
1%
HP
= 0.16% heat rate or 0.3% kilowatt
1%
IP
1%
LP
1% flow increase = 0.94% increase in kilowatts
1F (0.56C) temperature increase = 0.08% decrease in kWs and 0.024% better heat rate
(VWO)
1 Btu TEL (total exhaust loss) = 0.1% poorer heat rate
10F (5.6C) decrease in T
T
increases
HP
0.11%.
A 5% increase in stage pressure flow relationship is cause for alarm.
1% P increase in steam path = 0.1% poorer heat rate
A 1% change in P
1st
due to a change downstream indicates a 1.5% change in flow for a 1.25
pressure ratio control stage (Curtis stage, not single Rateau stages).
A 1% change in P
1st
due to a change upstream of the 2
nd
stage indicates a 1% change in flow .
Bench mark HP 2% is better than heat balance.
A 10% nozzle area increase due to SPE results in a 6% loss in stage efficiency for the control
stage and 34% for the other stages.
A 10% decrease in control stage nozzle area decreases the flow passing capacity by 3%.
% P SV and CV 4% (VWO)
% P IV 2%
% P crossover 3%
A 1% increase in HP and IP turbine stage pressures due to a restriction downstream of the
stage results in a 0.6% increase in pressure upstream for an impulse type stage and 0.7% for a
50% reaction stage.

1-25
1.5.5 Unit Start and Load Data
Unit start and load data are primarily used to assess (a) rotor life, (b) issues associated with creep
damage in the first HP or reheat stages, and (c) low-cycle fatigue in the last two or three rows of
the LP turbine, depending on the size of the blades and the loads they exert on the blade root
attachments. The condition assessment should evaluate the record of accumulated start-stop
events to determine the potential for these damage mechanisms to affect the future reliability of
the rotor components.
To perform the assessment, the number of hot, cold, and warm starts are gathered since the last
overhaul along with the unit service hours and recorded on Data Sheet #5. These totals (since the
unit went into commercial operation) should also be determined to assess creep (total hours) or
low-cycle fatigue damage (total start-stop cycles).
Unit start/load information for the time period from the last inspection can be entered into
Equation 1-1 to assess the potential need for a major inspection. This equation equates unit start
types and trips to equivalent operating hours (EOH) for a unit.
EOH = 20 x CS + 10 x HS + 5 x WS + SH+ 40 x FLT + 10 x LFLT Eq. 1-1
EOH = Equivalent operating hours
CS = Number of cold starts
HS = Number of hot starts
WS = Number of warm starts
SH = Synchronized hours since last overhaul
FLT = Number of unit trips above 75% of full load
LFLT = Number of trips on unit at less than 75% full load
(includes annual overspeed trip).
Using this formula, the maximum number of equivalent operating hours between outages should
not exceed 80,000 equivalent operating hours (EOH) for base load and load cycling units. This
assumes that unit condition is acceptable and that normal predictive/preventive maintenance and
system tests are being performed on the unit as specified by the OEM. It should be noted that
higher EOH might be allowed for newer designed machines. Experience may show that 80,000
EOH is not advisable in some situations, especially in supercritical HP and IP sections.
Judgment, experience, and a continuing condition assessment program for a unit should be the
basis for selecting EOH limits.
If detailed component life consumption models exist for the critical elements, such as blades and
rotors, this information can be used to determine the probability of problems due to creep, high-
and low-cycle fatigue, stress corrosion cracking, or other blade issues without having to use
Equation 1-1 above. The additional accuracy provided by such models offers a basis for
changing the turbine overhaul interval.

1-26
A partial list of research published by EPRI on turbine-generator unit start-up and loading is as
follows (organized by year of publication):
Variable Pressure Operation: An Assessment, EPRI, Palo Alto CA: 1990. GS-6772.
Steam Turbine Start-Up and Loading, EPRI, Palo Alto CA: 1998. CD-110966.
1.5.6 Unit System Steam/Water Purity
Inadequate control of steam or water purity can introduce contaminants into the steam path,
particularly at the LP section Wilson Line (wet zone), causing corrosion damage and/or
plugging to the steam path. As such, a change or deterioration in steam or water purity can affect
both reliability and output and therefore is included as a separate part of the condition
assessment.
Data Sheet #6 outlines the purity tests that are typically conducted and at what locations. In
general, purity is defined by measurements of:
Specific conductivity
Cation conductivity
Presence of sodium
Presence of silica
The pH level
Typical limits are identified on Data Sheet #6(a). Purity is monitored at the polisher or
economizer outlet, the main steam or reheat steam inlet, and the condensate pump discharge.
Any out-of-limit chemistry excursions that have occurred since the last assessment should also
be noted. If specific problems have been experienced, determine by means of the interview when
it occurred, how the problem was resolved, and then assess the impact on future turbine
reliability.
In terms of interpreting the potential impact of water impurities as a consequence to unit
condition, the following guidance is offered:
If a steam or water chemistry upset has occurred, there may be an increased risk of caustics,
sodium, chlorides, copper, or sulfates being deposited on steam path components.
Copper typically deposits in HP turbine sections with chlorides, sulfates, and caustics in the
LP section near the phase transition zone. These deposits can lead to pitting and eventually
stress corrosion cracking (SCC) or corrosion fatigue (CF) of turbine blades, wheel dovetails,
or other highly stressed rotating components. The leading indicators of this problem can be
determined by visual observation of pitting on LP wheels and blades and the coloration of the
deposit (white or light grey). Such deposits, if seen, should be analyzed to determine their
composition in that specific deposit at the stage in which they were located.

1-27
Copper deposition in the HP section can be determined by noting a gradual loss of steam
flow passing capability and turbine performance degradation. There have been cases where
copper deposits were removed by flooding the specific turbine section with a mixture of
ammonia and water. Several utilities have reported the success of such an activity.
A partial list of additional research published by EPRI on turbine-generator steam and water
purity is as follows (organized by year of publication):
Guide for the Use of Corrosion Resistant Coatings on Steam Turbine Blades, EPRI, Palo
Alto, CA: 1987. CS-5481.
Cycling, Startup, Shutdown and Layup Fossil Plant Cycle Chemistry Guidelines for
Operators and Chemists, EPRI, Palo Alto CA: 1997. TR-107754.
Steam, Chemistry and Corrosion in the Phase Transition Zone of Steam Turbines: Volumes 1
and 2, EPRI, Palo Alto CA: 1997. AP-108184.
Corrosion of Low Pressure Steam Turbine Components, EPRI, Palo Alto, CA: 2000.
1000557.
Turbine Steam Chemistry and Corrosion: Electrochemistry in LP Turbines, EPRI, Palo Alto,
CA: 2001. 1006283.
1.5.7 Lubricating Oil and EHC Fluid Testing
Contaminated lubricating oil can damage bearings, thrust runners, and rotor journals. It can also
cause problems on units that use lubrication oil in control systems, such as mechanical hydraulic
controls. This increases the risk of overspeed events and result in problems in other turbine
systems. Any sudden increase in particle count size, water, color, or neutrality number may
require plant actions to correct such problems before the turbine-generator experiences problems.
Data Sheet #7 is provided to guide the assessment of lubricating oil and EHC fluid condition. As
with the preceding data sheets, it begins with an audit #7(a), moves to the interview with the
system specialist in #7(b), and concludes with an assessment of the risks and recommendation of
action in #7(c).
Typical problems that can be experienced due to contaminated lubricating oil or EHC fluid are
discussed below.
Lubricating oil:
A copy of the lubricating oil particle counts, water neutralization number, and color should
be obtained, and this data should be recorded on Data Sheet #7a. Oil samples are normally
taken near the booster oil pump or eductor, on the inlet side of the oil tank return screens and
from the discharge side of the oil purification system.

1-28
These values should be trended and compared against the OEM limits. High particle counts
can result in scored journals and increase the risk of bearing wipes (thrust and heavily loaded
journal bearings) along with having a detrimental affect on the hydraulic control system. The
control system components can seize due to dirt accumulation and, in some severe cases, fail
to properly function during transient events on the machine.
Water in the lubricating oil can result in reduced oil film thickness at operating speed and
loss of insulation on generator and exciter bearings and the insulated hydrogen seal casing.
Electrical discharge from the journals to the bearing babbitt material can result in the frosting
of bearings and journals and increase the risk of a wiped journal or thrust bearing during unit
operation.
Contaminated lubricating oil can be corrected by installing a vacuum dehydration system at
the oil tank to remove both water and particles from the oil. There are recirculation pump and
filter units that can be installed at the oil tank to clean particles from the oil. These actions
will clean the lubricating oil, but they do not clean the piping, which may also be
contaminated.
EHC Fluid:
A copy of the EHC fluid sample test results should be obtained and recorded on the same set
of data sheets. It is important that fluid quality be maintained within the limits specified in
Table 11-1 of the EPRI report EHC Fluid Maintenance Guide (1004554) to prevent
hydrolysis on valve spools. Hydrolysis can cause sticking or binding of EHC components or
cause stress corrosion cracking in stainless steel parts of the EHC system. A copy of this
table is shown on the next page for reference.

1-29
EHC Test Results
Parameter
1
EPRI Frequency Reference Achievable
2
Comments
Color Limit of 4.0 max
or monthly
increase of 0.5
Monthly 4.4.3.1 1.5 (Light Tan) ASTM D-1500 Color Criteria; OEMs limits are included in
Appendix H. Fluid Color Scale Comparison Chart is
included in Appendix G5.
Viscosity +/- 10% initial
value
Monthly 4.4.3.2 N/A System contamination measurement most important after
breach of system
Acidity
(mg KOH/g)
< 0.1 Monthly 4.4.3.3 < 0.05
Chlorines
(ppm)
< 50 Quarterly 4.4.3.4 < 10 System contamination measurement most important after
breach of system
Water
(%, ppm)
< 0.1,
1000ppm
Monthly 4.4.3.5 < 0.05,
500ppm
2 main methods for improving this are dry air purge and
vacuum dehydration
Mineral Oil
3

(%)
< 0.5 Quarterly 4.4.3.6 <0.1 System contamination measurement most important after
breach of system
Resistivity
(G-Ohm-cm)
> 5 - 10 Monthly 4.4.3.7 > 20 Can cause erosion problems on stagnant areas of system,
fluid types have different values
Particulate
4
<2K/100 ml
of 5-10
micron
5

Monthly 4.4.3.8 1K/100 ml
of 5-10
micron5
EPRI value is a good starting point for developing fluid
monitoring, but it has to have consistent sample methods
and points
Individual
Metals
(per metal)
< 10 ppm 6 Months 4.4.3.9 < 2 ppm Not a routine check, but indicative of degrading system,
exclude phosporus and chromium. If particulate or acid #s
increase then increase the frequency of metal testing.
Foaming
(Height/Colla
pse time)
< 100 ml/
< 5 minute
12 Months 4.4.3.10 N/A Collapse time is reported as time to get to nil foam height
Air Release < 10 minutes 12 Months 4.4.3.11 < 8 minute Should be performed with the system health check. With
natural fluids < 5 minutes is achieveable.
Hexane Test
6
B8 2 Years 4.4.3.12 B2/B3 Indicator of heat related problems
NOTES:
1. Any one parameter out of the recommended values does not condemn a fluid or system. The collective data is what determines if a fuild or system is of concern. More than
2 parameters outside of the values would require evaluation to determine the total affect. Test methods are specified in Table 4-10 in section 4.4 of EPRI report 1004554.
2. Achievable values normally require system modifications and upgrades.
3. Some standard tests (GE) do not report only mineral oil, but generate a number that includes other non-soapontifiables (fluid degradation by products).
4. If this parameter doubles from one sample to the next then a new sample is needed per the EPRI sample procedure in section 4.2.2 of EPRI report 1004554.
5. ISO cleaniness code equivalent numbers are not available at this time due to changes in calibration test dust and the techniques which had been used in the most previous
testing.
6. Rate according to ASTM D-2276 Appendix A3 B scale for aviation turbine fuels going from B-0 (white) to B-10 (very dark brown to black).

1-30
Follow-up actions should be taken if these recommendations for EHC cleanliness are
exceeded. Efforts should be made to ensure that EHC pumping system components are on a
fixed PM schedule and they are inspected and repaired when recommended limits are
reached.
It has been shown that high water content in the EHC fluid can be minimized by pressurizing the
EHC tank with instrument air at a pressure of 2 inches (50.8 mm) of water above atmospheric
and the fullers earth filter is operated as recommended by the OEM. In addition, if maintenance
is frequently performed to servo valves and valve actuators during overhauls, the plant needs to
have a foreign material exclusion (FME) program to prevent system contamination.
A partial list of EPRI research published on lubricating oil and EHC fluid testing is as follows
(by year of publication):
Lube Oil System Leakage Mitigation, EPRI, Palo Alto, CA: 1999. TR-111413.
Lubrication Guide: Revision 3 (Formerly NP 4916-R2), EPRI, Palo Alto, CA: 2001.
1003085.
Electrohydraulic Control (EHC) Fluid Maintenance Guide, EPRI, Palo Alto, CA: 2002.
1004554.
Turbine Oil Lubrication Compatibility Testing, EPRI, Palo Alto, CA: 2004. 1011028.
Turbine-Generator Auxiliary Systems Maintenance Guides: Lube Oil System
Maintenance Guide, EPRI, Palo Alto, CA: 2005. 1010191.
Electrohydraulic Control (EHC) Fluid Elastomer Compatibility Study, EPRI, Palo Alto,
CA: 2005. 1011823.
1.5.8 Pump Testing
The lubrication system in a turbine-generator includes a variety of pumps that work
continuously. The loss of or inadequate oil pressure can result in significant damage to bearings
and turbine-generator internal components if a unit is tripped and rolls down from operating
speed. Inadequate oil pressure (normal pressure is 25 psig (172 kPa) at the turbine centerline) can
result in increased bearing metal temperatures and sluggish operation of the MHC control
system.
To assess the condition of these components, eight pumps are identified on Data Sheet #8:
AC auxiliary oil pump
Turning gear oil pump
DC lubricating oil pump
Main seal oil pump
Recirculation seal oil pump
DC seal oil pump

1-31
Stator cooling pump
EHC pump
The assessment should review and record start results on all pumps in the lubricating oil, seal oil,
EHC, and stator-cooling systems as recommended by the specific OEM.
The pump condition should be assessed based on start test data, which includes the frequency of
starts, the results of the test, and their comparison to acceptance criteria. Interviews should be
conducted with operators and maintenance personnel responsible for PM or PdM on these pumps
in order to determine if they are being tested, operated, and maintained in accordance with
internal organizational or OEM requirements. Also, it should be determined if there are issues
with these pumps that could result in the potential for a forced outage on the machine.
In terms of evaluating the information gathered in the assessment, the following are offered as
guidance:
A spot check of EHC or lubricating oil pump discharge pressures or at the turbine centerline
should be taken and reviewed to ensure that they are within prescribed limits noted in the
specific OEM instruction book.
Pumps not meeting minimum OEM requirements should be recommended for inspection
and/or corrective action. Action should include checking the pressure switches that initiate
starting for correct actuation or repair/replacement at the next inspection if conditions dictate.
If these pumps are not being tested, a recommendation should be made to initiate testing in
order to minimize the risk of operating failures when these pumps are required to function as
intended.
A partial list of EPRI research on turbine-generator pumps is as follows (by year of publication):
Symposium Proceedings: Power Pump Plants, EPRI, Palo Alto, CA: 1988. CS-5857.
Power Plant Pump Repair Guideline (Interim Report), EPRI, Palo Alto, CA: 2000.
SV 113418-OL.
Pump Troubleshooting, Volumes 1 and 2, EPRI, Palo Alto, CA: 2000. 1000919.
Vertical Pump Maintenance Guide: Supplement to NP-7413, Deep Draft Vertical
Centrifugal Pump Maintenance and Application Guide, EPRI, Palo Alto CA: 2002.
1003467.
1.5.9 Turbine Steam Valve Test Results
A turbines governing system controls the steam flow through the unit by small adjustments to
the control or governor valve positions. Governing valves and control valves admit steam to the
nozzles of the first stage. Stop or throttle valves isolate the turbine sections from their steam
supply in the event of load loss. Intercept and reheat stop valves control the flow of LP inlet
steam during rapid load changes or overspeed events to prevent reheat steam from entering the
LP turbine. Locations of common turbine control elements and valves discussed in this portion
of the assessment procedure are shown in Figure 1-4.

1-32
If the turbine inlet steam flow is maintained in the event of a loss of generator load, the rotor can
accelerate to destructive overspeed within seconds. Periodic valve open/close tests and tightness
tests are therefore necessary to ensure smooth valve operation in the event of emergency loss-of-
load situations. Valve deterioration can also play a role in the thermal efficiency and
performance of the turbine.

Figure 1-4
Location and Function of Basic Turbine Controls
Data Sheet #9 is used to guide the assessment, specific to the control, main stop, reheat stop,
intercept, and non-return valves that may be found in a unit. Basic acceptance criteria are
identified that focus on the fundamental problems that typically affect valves.
The more common valve problems to be aware of when assessing valve condition are:
Broken valve stems are typically found immediately because there is an abrupt change in
throttle flow, section efficiency, and unit load. Unless corrected, the unit output will likely
remain restricted.
In the case of fossil units, valve stems can become stuck due to oxidation and corrosion on
the stems and bushings, resulting in zero stem bushing clearance. Another cause for sticking
may be stem bending due to residual stress caused by manufacture or steam bending/side
loading forces acting on the stem. Different symptoms may be observed depending on where
in the stroke stem the stem sticks. For example, if a control valve stem starts to stick just as
the valve opens, the operator will see no increase in throttle flow or load at the valve crack
points. The stem may eventually move slowly and make irregular changes in load and flow,
thus causing difficulties in load control. It should be recommended that this condition be
corrected as soon as possible.
External leaks are principally due to improper gasket compression or broken valve bonnet
studs. Valve conditions such as these normally take one to two days to correct, but can take
at least five days if studs are found to be cracked and need to be replaced. The consequence
of this type of valve degradation is lost generation to make repairs, which may be significant,
depending upon when the maintenance is scheduled.

1-33
Internal steam leakage occurs primarily as a result of the deteriorated condition of the valve
disk and seat. Leakage can be due to:
Valve disk or seat distortion
Damage to the valve seat or contact surfaces
Improper setting of the controls that results in the disk being lifted off the seat when the
valve is in a closed position setting
Bent/broken valve stems, which cause the valve to stick open slightly when the valves
have been given a control signal to close
The consequence of valve internal leakage can be an overspeed of the unit during operation
or prevention of the unit from going on turning gear. Valve leakage can be checked by first
opening and closing valves with pressure applied to the valve being tested and then recording
turbine shaft speed. An increase in shaft speed indicates internal leakage. Valves should be
leak tested in accordance with OEM recommendations.
Failure of the valves to close when tested means there may be a significant increase in the risk of
a turbine overspeed event (worldwide, the failure of valves to close has resulted in numerous
overspeed events). Such risks have such catastrophic potential that a valve problem should be
corrected no later than the next unit weekend shut down.
For fossil units, it is recommended that open/close tests be performed weekly on all valves.
Functional tests on the main stop, intercept, and reheat valves should be performed weekly.
Control valves should be closed weekly. Tightness tests are normally recommended on the main
stop, control, and intercept valves on a 612 month interval to ensure minimal steam leakage by
these valves.
Nuclear valves may be tested at intervals that are different from those for most fossil valves.
Typically, open-close tests are performed at OEM-recommended intervals, with tightness tests
performed on the governor (control) valves and on the main stop (throttle) valves on a 612
month basis. Most GE valves have specific criteria for testing tightness. For example, a GE
nuclear main stop valve is considered tightly closed when turbine speed reduces to less than two-
thirds of rated speed. If the valve does not completely close and if speed stays at more than two-
thirds of rated speed, the valve condition should be monitored. Eventually, a valve may not pass
the tightness check. If this occurs, corrective action should be taken as soon as possible. A GE
nuclear control valve is considered tightly controlled when speed reduces to one-third of rated
speed or less. If the unit cannot go to turning gear, corrective action should be taken at the next
outage. If shaft speed during the test is greater than one-third of rated speed, action should be
taken sooner.
SWPC nuclear valves may have different acceptance criteria; thus, OEM recommendations
should first be followed. If no criteria are provided, the acceptance criteria described above for
GE nuclear valves should be used.
The frequency of valve testing can be increased, depending on a units particular experience.
However, if the interval is extended too much, the risk of an overspeed event may be increased

1-34
significantly. Valve tests prove that the control system is functioning properly and that valves
will close without sticking. If any part of the above tests fail, then the first and second lines of
defense against overspeed have been compromised.
All machines should be wired so that the generator breaker is not opened until the valves are
clearly indicated as closed (the generator is allowed to motor for 3 to 5 seconds, for example).
This very simple feature added to the trip system logic could have prevented many units located
in the United States from experiencing overspeed events. Numerous technical bulletins by
turbine-generator OEMs have been published on this subject.
The condition assessment should thoroughly review the results of these tests performed by
operations, or if they have not been performed, have them conducted during the annual review.
Appropriate comments should be made in the specified areas on the data sheets. As noted, valves
not meeting the criteria specified should be recommended for inspection at the next unit outage
or, if severe enough, at the next weekend shutdown of the machine.
For additional information relating to valve testing and maintenance, refer to the valve primer
found in the EPRI report Guidelines and Procedures for Steam Valve Condition Assessment
(1008352).
A partial list of EPRI research on turbine-generator valves is as follows (organized by year of
publication):
Guidelines and Procedures for Steam Valve Condition Assessment, EPRI, Palo Alto, CA:
2004. 1008352.
Turbine Steam Valve Diagnostics Testing, EPRI, Palo Alto, CA: 2004. 1004960.
1.5.10 Overspeed and Trip Checks
In all turbines, loss of turbine speed control can result in overspeed and a risk of rotor failure.
Overspeed and trip checks are the front line of defense against the risk of a catastrophic turbine
failure. The turbine control system must therefore always operate properly and reliably. This
condition assessment task is meant to evaluate the present capability of the control system to
rapidly isolate the main turbine from the boiler/reheater/reactor and/or the moisture
separator/reheater (MSR) steam supply.
Data Sheet #10 identifies a minimum of five trip tests:
Overspeed trip
Minimum oil trip
Vacuum trip
Solenoid trip
Shaft pump trip

1-35
Other trip devices, like those listed below, may also be installed on particular units. Locations of
these common trips are shown in Figure 1-4.
The overspeed trip backs up the normal speed-governing system, including the main and pre-
emergency speed governors, and is activated only when control or governor valves cannot act
rapidly enough.
The low bearing oil pressure trip guards against wiping the main bearings when the
lubrication fails by activating the emergency shutdown systems and promptly closing all
steam valves.
The low vacuum trip closes every steam valve in the turbine if the exhaust vacuum falls
below a set allowable pressure.
The solenoid trip shuts down the turbine by closing all valves.
The thrust trip measures the position of the rotor relative to the thrust-bearing cage and trips
the emergency shutdown systems if the position deviates from safe limits.
It should be confirmed in the interview with operations that all turbine-generator trips noted in
the audit were performed properly. The trip speeds or acceptability of the test for each trip
should be indicated, along with the date on which the test was performed. Any other pertinent
operational tests not specified in this data sheet (#10) should be recorded along with the results
of these tests.
In terms of completing the assessment, failure of any trip device to actuate is cause for
immediate action to be taken by the plant to correct the problem. Otherwise, the risk of
catastrophic failure of the unit is significantly increased.
A partial list of EPRI published research related to turbine-generator overspeed and trip testing is
as follows (by year of publication):
Development of a Risk Monitor for Assessing Plant Trips, EPRI, Palo Alto, CA: 2002.
1003117.
Risk Evaluation of Steam Turbine Destructive Overspeed, EPRI, Palo Alto CA: 2003.
1008740.
Turbine Overspeed Risk Management and Reliability Improvement Workshop, EPRI, Palo
Alto CA: 2003. 1009333.
Trip Monitor Customization and Implementation Guideline, EPRI, Palo Alto, CA: 2004.
1009112.

1-36
1.5.11 Instrument Surveys
Supervisory instruments installed on the turbine and its piping monitor the condition of the steam
as it flows through all parts of the overall cycle and the condition of the turbine stationary and
rotating elements. Wide ranges of instruments are available; some are simple indicators, others
are integrated with recorders, and still others are integral parts of the automatic turbine control
system. This portion of the condition assessment is meant to evaluate and ensure that the unit
operators have adequate, accurate instrumentation to make operating decisions during times
when unexpected transient events occur. The location of typical turbine supervisory
instrumentation found on the turbine is shown in Figure 1-5.

Figure 1-5
Location of Typical Turbine Supervisory Instrumentation
The instrumentation that should be audited is as follows (see Data Sheet #11):
Shaft differential expansion and position data at minimum and full load
A histogram plot of temperature versus time in minutes should be made of various
thermocouples specified by the OEM (first stage inner metal, valve bowl) in their start and
load instructions in order to ensure that the temperature ramp rates are being correctly
followed by operations. This ensures that the turbine is being started and loaded correctly,
thus minimizing the risk of startup rubs, rotor-long or rotor-short problems, and reduction of
rotor bore life during the critical startup period.
Lubricating oil system pressures should be noted at the turbine generator centerline and oil
tank.
A plot of water induction thermocouple temperature differential is useful to assess whether
water induction problems are possible during a startup to minimum load. Such data
superimposed over turbine vibration and rotor or casing expansion should clearly identify if
potential problems (rotor short, rotor long) could occur during hot, warm, or cold starts.

1-37
During an assessment of these instruments, data should be checked and recorded at full load. In
addition, a plot of data from each of the instruments should be obtained from the unit historian
during a typical unit startup and reviewed to ensure that they function as designed. Typically,
such plots during a cold start are more informative because more problems are likely due to the
larger thermal transients and operational problems that can occur.
In reviewing start and load data, the engineer or technician should be looking for the following:
Expansion data. Is casing and rotor expansion smooth, or is there sudden movement during
startup and ramp to load? Such jumps in expansion can be due to excess friction between the
pedestal and sole plate. It can also be used, when superimposed over water induction
thermocouple temperature differential plots, to determine if water induction problems
potentially exist.
Historian plots of first stage inner metal temperatures. Along with other OEM temperatures
specified in their start and load instructions, these plots ensure that the OEM-specified ramp
rates and hold times are being followed for the machine. Higher-than-expected ramp rates or
shorter-than-expected hold times at specified speeds increase the rotor peripheral and bore
life consumption, thus increasing the risk of future serious problems during unit operation. It
also increases the risk of rotor short or rotor long problems, which can cause axial rubs in the
various turbine sections.
Oil pressures: Compare oil pressures at the various locations to expected values. Significant
differences in actual versus expectedcoupled with gauges out of calibrationrequires that
corrective action be taken.
Thermocouple temperatures: Evaluate thermocouple temperature readings to be sure that
they make sense and are at expected values. Significant discrepancies warrant a
recommendation to calibrate or replace defective thermocouples because these are relied on
by operators to warn of the need to take corrective actions when transient events occur.
A general review of the data gives the unit engineer/technician an immediate indication of the
condition of the information that operators use to operate and maintain the health of the machine,
especially during transient events where damage could occur to the unit. Obvious problems with
this instrumentation require a recommendation to take corrective action on at least an
intermediate basis.
A partial list of EPRI published research on turbine-generator instrumentation is as follows (by
year of publication):
Guide for Monitoring Equipment Environments During Nuclear Plant Operation, EPRI, Palo
Alto, CA: 1991. NP-7399.
SysMon 2.0 Users Guide: System Monitoring by Systems Engineers, 37 System Templates,
EPRI, Palo Alto, CA: 2000. 1000260.
Equipment Condition Assessment: Vol. 1 - Application of On-Line Monitoring Technology,
EPRI, Palo Alto, CA: 2004. 1003695.

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Equipment Condition Assessment: Vol. 2 - Technology Evaluation and Integration, EPRI,
Palo Alto, CA: 2004. 1009601.
Implementation Guidelines for On-Line Monitoring, EPRI, Palo Alto, CA: 2004. 1003361.
Modeling Guidelines for On-Line Monitoring, EPRI, Palo Alto, CA: 2004. 1003579.
1.5.12 Generator Electrical Operating Data
Most generator issues are mechanical or thermal in nature and, in turn, become electrical
problems as the dielectric strength of the insulation degrades. The mechanical issues do not
always lend themselves to early detection by electrical testing, but they may produce some
visible effects that are discernable during service. This portion of the condition assessment is
meant to evaluate the present condition of the generator, based primarily on electrical operating
data and measurements that are taken during unit operation.
The control room monitors the key parameters of:
Stator current
Stator voltage
Output (MW)
Reactive power output (MVA)
Power factor (PF)
Safe operating levels for a specific generator are defined by design curves supplied by the OEM,
where the MW, MVA, and PF are applied. An example showing the general format of these
design curves and how their limits are established is shown in Figure 1-6.

1-39

Figure 1-6
Typical Generator Capability Curve
Generators are typically designed for some voltage variation. An OEM may specify a 5% over-
or under-voltage design rating. Abnormal voltage operation causes damage due to increased flux
heating densities and core heating. Under-voltage operation requires increased excitation and
may result in additional wear/damage to the excitation system.
Data Sheet #12 further organizes the electrical inspections of generators into those associated
with (1) the stator and (2) the field and exciters: DC, Alterex, and brushless.
The stator core serves a mechanical and electrical purpose. Mechanically, it supports the
windings. Electrically, it provides a return path for the lines of magnetic flux induced by the
field. The generator field produces an electrical potential induced during normal operation. Shaft
grounding brushes are usually installed near the coupling between the turbine and generator to
provide a ground path for the potential difference.
Temperature monitoring of the stator windings is normally done with resistance temperature
detectors (RTDs) that are embedded within the stator slots. Thermocouples (TCs) measure inlet
and exit water temperatures for generators with water-cooled windings. Allowable limits are set

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as a maximum temperature for the exit water, as well as the differential temperatures between the
inlet and exit. Gas-cooled windings generally have the same arrangement. In the audit portion of
the assessment, temperatures should be recorded at full load. The number of RTDs and TCs out
of service should also be noted and whether the failure rate is considered normal or unusual.
Stator winding availability is most often compromised by looseness caused from vibration.
Monitored vibration readings should therefore be noted and compared to trend changes against
what values are expected from past service.
Partial discharge data are an indicator of deterioration or degradation of the windings. A partial
discharge occurs because there is still some insulation left, whereas a complete breakdown would
lead to a ground. Individual units will have their own signature and unique condition, so actual
partial discharge levels are trended over time to assess the condition of the winding insulation.
A meggering (megger) test reports insulation resistance where any conducting paths within the
insulating system being tested result in current flow and a reduction in the meter reading. A high
reading does not necessarily indicate that the equipment can withstand the operating or rated
potential since the megger uses a potential much lower than the rated potential. The megger
should provide an index of the insulating material through a dielectric absorption test, that is, a
measure of dryness of the winding. The ratio of the 1-minute and 10-minute readings is known
as the polarization index (PI). The periodic resistance readings are trended to indicate impending
insulation failures. PIs above 2.5 for the stator and 1.25 for the field are considered acceptable.
Stator current should never be allowed to exceed the nameplate values. All phases should remain
equally balanced. A condition of phase unbalance (a nonsymmetrical magnetic field) can cause
negative sequence currents that may overheat one phase of the stator. The amount of damage to
the field will be dependent on the magnitude of the negative sequence current imposed on the
field. If additional heating occurs in the rotor surface, it can cause further damage to the wedges
and retaining rings. These conditions can also occur during a ground fault incident.
The generator field operates with direct current (dc) fed into the rotor windings from an
excitation source, the exciter, through a brushless excitation or a carbon brush and collector ring
system. Rotation of the shaft across the dc winding field creates the rotating flux field that
induces both current and voltage at the stationary coils of the stator, which has been previously
discussed.
Generator internal clearances are not typically close enough to result in damage from excessive
vibration (mechanical or thermal imbalance) during operation, except in the bearing and sealing
areas. Generator bearings may experience the same problems as turbine bearings. One bearing,
usually the collector end bearing will be insulated. This bearing should be checked with a 500-
volt megger. A minimum of 100,000-ohms resistance is required.
Potential vibration problems due to thermal sensitivity are determined by monitoring rotor
vibration with changes in load (or VAR output). On-line flux probes can identify the presence of
shorted turns

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The generator field collector rings should be checked for vibration to provide an overview of
their condition. A good operating collector ring/ brush assembly will have vibration levels in the
range of 23 mils (0.050.08 mm). Up to 6 mils (0.15 mm) is satisfactory. Readings of 1020
mils (0.250.51 mm) may be experienced when there are problems.
High collector ring vibration levels may mean mechanical problems with the rings. The
amplitude of vibrations will normally increase as collector rings wear. Often, however, this is
more a reflection of the condition of the rings. Damage manifests itself as peaks and valleys
caused by the brushes. Grinding the collector rings will restore the rings to a round condition.
A high collector ring wear rate would indicate both mechanical abrasion and electrical arcing as
the brush contact begins to degrade. The brushes tend to chatter and chip as temperatures rise
from loss of contact as the condition worsens.
The hydrogen leakage test reports the amount of hydrogen consumed during operation that is
absorbed into the seal oil or lost through leakage at the seals or other locations. Damage to the
hydrogen seal will reduce sealing capacity and increase hydrogen consumption. Seal oil flow
(absorption) is usually 515 gallons per minute (gpm) (18.956.8 liters per minute or lpm). If the
absorption rate is less than 5 gpm (18.9 lpm), this indicates tight seals that may easily be
damaged. A rate greater than 15 gpm (56.8 lpm) means that the seals are open, and when
combined with air-side losses, the seal oil requirements may exceed the seal oil supply pump
capacity. Acceptable gas loss (leakage) is generally <1000 cubic feet (28.31 cubic meters) per
day. If seals are too open, oil leakage may occur into the generator stator and also result in liquid
level alarms on the generator.
In evaluating the present condition, the assessor should take note of the following issues or
problems that may potentially affect generators:
Vibration (related to the rotor winding system) is primarily a consequence of mechanical
unbalance or uneven cooling and heating in the rotor winding and body. Thermal instabilities
result from (a) blocked cooling passages, (b) localized temperature changes due to multiple
shorted turns, or (c) other temperature instabilities that result in uneven growth of the copper
windings. With regard to unbalance, multiple shorted turns are one of the most common
sources of vibration in which the temperature decrease in the shorted turn slot causes less
expansion and causes the rotor to bow.
Thermal aging is the principal cause of the degradation of rotor winding insulation. The
deterioration is a combination of high temperature, long operating time, and mechanical
stress.
If the shaft grounding system is not functioning properly, the potential difference between the
rotor and stationary components will naturally seek an alternative path through the oil film of
the bearings or the hydrogen seal. The result will be electrolysis at either location. It is
important to monitor the grounding brushes during normal operation, ensuring that they are
clean and in good contact with the rotor.
Loss of field excitation can produce severe heating in the rotor. Without excitation, the unit
becomes an induction generator, where significant surface current is induced in the rotor
body and wedges. The consequence may be arced or burned wedges.

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In evaluating the risk and need for action, the assessor should be aware of the following
circumstances where additional components of the unit may be affected by the condition of the
generator:
If the generator is supplied with excitation and system power, but the turbine loses the
driving force from the steam, the generator can effectively operate as a synchronous motor
and drive the turbine at rated speed. This is known as motoring. It is not necessarily harmful
to the generator, but it may damage the turbine. No cooling of the turbine blades will occur
with the steam flow blocked. If the blades rotating at rated speed have large tip diameters,
they may heat up rapidly in the stagnant atmosphere.
Off-frequency operation may also have a more detrimental effect on the turbine than on the
generator. The blades of various stages in the turbine may be tuned to operate within a
reasonably narrow operating speed (or frequency). Off-speed operation of those stages may
induce harmful stimuli to the blades, resulting in resonant fatigue failures.
Transients and faults may result in high rotor currents and resulting temperature increases,
but physical or mechanical damage may result from sudden changes during operation. The
mechanical shock induced by strong changes in the magnetic field may distort end turns,
loosen or break end turn ties, shift end turn blocking, or damage insulation.
In additional to the generator repair specifications found in Section 8 of Volume 2, a partial
listing of EPRI published research on generator operation and testing is as follows (by year of
publication):
Demonstration of an Alternative ASME Steam Turbine Generator Acceptance Test, EPRI,
Palo Alto CA: 1985. CS-4410.
Synchronous Machine Operation with Cutout Coils, EPRI, Palo Alto CA: 1987. EL-4983.
Generator Unbalanced Load Capability, EPRI, Palo Alto CA: 1991. GS-7393.
Main Generator On-Line Monitoring and Diagnostics, EPRI, Palo Alto CA: 1996. TR-
107137.
Generator Stability Parameter Identification Data Acquisition System (PIDAS): Volumes 1 -
3, EPRI, Palo Alto, CA: 1996. TR-106902.
Generator Core Overheating Risk Assessment, EPRI, Palo Alto CA: 1999. TO-113531.
Guide to Rotating Electrical Machine Hipot Testing: Draft Report, EPRI, Palo Alto CA:
2000. 1000666.
Voltage Unbalance: Power Quality Issues, Related Standards and Mitigation Techniques:
Effect of Unbalanced Voltage on End Use Equipment Performance, EPRI, Palo Alto, CA:
2000. 1000092.
Partial Discharge On-Line Testing of Turbine-Driven Generator Stator Windings: A guide
for the Use of Partial Discharge in Assessing the Condition of Generator Stator Windings,
EPRI, Palo Alto CA: 2000. 1001209.

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Testing of Stator Windings for Thermal Aging, EPRI, Palo Alto CA: 2000. 1000376.
Tools to Optimize Maintenance of Generator-Excitation System, Voltage Regulator and Field
Ground Protection, EPRI, Palo Alto CA: 2002. 1004556.
Generator Rotor Slot Dovetail Inspection and Risk Assessment, EPRI, Palo Alto CA: 2003.
1008222.
Guide for On- and Off-Line Testing and Monitoring of Turbine Generators, EPRI, Palo Alto,
CA: 2004. 1009406.
Generator On-Line Monitoring and Condition Assessment, Partial Discharge and
Electromagnetic Interference, EPRI, Palo Alto, CA: 2006. 1012216.
Steam Turbine-Generator Torsional Vibration Interaction with the Electrical Network. EPRI,
Palo Alto, CA: 2005. 1011679.
Torsional Interaction Between Electrical Network Phenomena and Turbine-Generator
Shafts. EPRI, Palo Alto, CA: 2006. 1013460.
1.5.13 Auxiliary Systems Data
Auxiliary systems addressed in this part of the overall assessment are (1) the overall steam seal
system, (2) the generator hydrogen seal oil system, and (3) the generator stator cooling water
system. This portion of the condition assessment is meant to review the mechanical integrity of
the two principal sealing systems found on the turbine and generator and to determine that the
generator stator is being cooled effectively.
Data Sheet #13 organizes the audit of the steam seals, hydrogen seal oil system, and stator
cooling systems into three parts.
Steam Seals: Leaks in the shaft steam sealing system may result in steam entering the lubricating
oil system, thereby increasing its water content and resulting in the problems identified in
Section 1.5.7.
Steam leakage past the steam seals is typically due to either (a) improper adjustment of the steam
seal pressure and/or vacuum at the regulator or (b) the steam seals have experienced a rub, thus
increasing the shaft-to-seal clearances.
The best way to initially determine if a problem exists with the steam seal system is to walk the
turbine deck during a startup of the machine and observe if steam leakage by the packing cases
or gland is occurring on a frequent basis. This can also be determined through interviews with
operators who have also observed unit startups in this manner. To confirm the possibility of a
steam seal leakage problem, inspect the lubricating oil at the oil tank to determine if water is in
the oil. The oil will be yellow to orange in color if excessive water is present.
In addition to contamination, a large steam seal leak can also result in unexpected heating of the
pedestals. The resulting thermal expansion, in turn, may introduce changes to the alignment of

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the turbine bearings. In the vibration signature, this may appear as symptoms of misalignment,
but it is indirectly related back to the leakage and overheating that is occurring. If steam leakage
is seen at the packing cases or glands, a recommendation should be made to take corrective
action during the next outage or a weekend shutdown, depending on the degree of the steam leak.
Corrective action while the unit is operating involves adjusting steam seal pressure at the steam
seal regulator (steam feed or unloading valves) and adjusting the vacuum at the steam packing or
gland exhauster. Reliance on the plant instruction book is recommended. Corrective action with
the unit off gear is to take feeler checks between the shaft and the steam seals using a feeler gage
to be sure that excess clearances are not present that result in steam leakage even if seal pressure
and vacuum are properly set. If this is found, it may be necessary to replace the labyrinth seals
during a unit outage. In the interim, frequent lubricating oil checks should be performed to
ensure that less than 1,000-ppm water is maintained in the lubricating oil. This may require
connecting a vacuum dehydration unit to the lubricating oil system to achieve the required water
content in the lubricating oil.
Hydrogen seal oil system: The purpose of the system is to maintain the hydrogen pressure inside
the generator. The primary issue of concern to the assessor is contamination of the lubrication
and the reliability issues this raises that are associated with the generator.
Leakage can be due to:
Problems in maintaining seal oil pressure differential
Excessively worn hydrogen seals or excessive inner oil seal problems
Hydrogen seal casing and outer end shield contact problems on vertical and horizontal joints
Failure of a float valve in the closed position or hydrogen seal oil cooler tube leaks
(depending on whether water is seen in the seal oil)
Water may also be a result of excessive steam seal leakage or lubricating oil cooler leaks if the
hydrogen seal oil coolers have no problems, or it may be from failure of the vacuum pump. From
a long-term perspective, oil ingress into the generator is detrimental to stator coils because oil
causes the coils and wedges to become loose and thus vibrate and wear at a faster rate than
normal, causing a potential re-wedge/rewind or more than normal damage to the end winding
system during overhauls.
Maintenance of hydrogen purity is important in order to prevent a possible explosion and fire. If
purity is less than 90%, a recommendation for immediate shutdown should be made to correct
the problem. A review of instruction book recommendations regarding hydrogen purity problems
should be thoroughly reviewed. Excess hydrogen leakage (twice the design leakage rate) should
be checked and corrected during a weekend shutdown or during a unit outage.
A vibration problem during startup/shutdown could be related to unbalance or generator thermal
problems causing bowing of the rotor at high load and field current. The extent of this problem
depends on the level of vibration at load and during roll-up/roll-down. This requires immediate
corrective action since generator and turbine parts can be rubbed or damaged, causing future

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problems. If problems are found, a review of the vibration data should be performed to determine
if the generator has a thermal vibration problem or a mechanical unbalance problem as it passes
through its critical speeds.
The best method to determine the health of the hydrogen seal oil system is to question plant
operators about the system and maintenance personnel about PM and PdM checks that are
performed.
Intermediate recommendations should be made if no such programs exist or if problems found
during such inspections have not been corrected.
Stator cooling water system: The purpose of the assessment is to ensure that the water system
will maintain an adequate supply of cooling to the stator conductors.
Condition is assessed based on an audit of water conductivity, pressures, and temperatures and
stator bar temperatures. Criteria for each are noted on the audit portion of the data sheets. It
should be noted these values may vary with the unit and should therefore be checked against the
OEM specifications.
The basic condition of the stator cooling water system can be determined by interviewing the
operators and plant maintenance personnel who have responsibility for stator cooling system
PM/PdM programs.
Any instrument that does not function properly requires immediate actions to correct the problem
because these protect the stator from failure of the stator coils.
Intermediate action is generally necessary if a reasonable PM/PdM program is not being
performed on the equipment. No short-term recommendations are necessary if the system
appears to be in good condition, if operators have performed tests as recommended by the OEM,
and if maintenance programs are adequate for the system.
There may be long-term recommendations by the OEM that improve the stator cooling systems
reliability and performance. If such an OEM recommendation exists, it should be implemented
during the next major overhaul if it is technically and economically reasonable.
A partial listing of EPRI published research on auxiliary systems (steam seals, hydrogen oil
seals, and the generator stator cooling system) is as follows (by year of publication):
Primer on Maintaining the Integrity of Water-Cooled Generator Stator Windings, EPRI, Palo
Alto, CA: 1995. TR-105504.
Preventing Leakage in Water Cooled Stator Windings (Phase 2), EPRI, Palo Alto, CA: 1998.
TR-111180.
Prevention of Flow Restrictions in Water Cooled Generators, EPRI, Palo Alto CA: 2001.
1006684.
Water Chemistry Tutorial for Generators, EPRI, Palo Alto, CA: 2003. 1007765.

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1.5.14 Component Visual Inspections
Although the condition assessments described in this section are meant to be performed based on
data obtained while a unit is in service, there are opportunities to make certain visual checks at
the turbine inlets and exhausts areas without a full teardown of the sections. It is always
recommended that plants take advantage of these opportunities although it may be possible to
verify and/or isolate a specific problem indicated by the sensors and tests discussed in previous
sections.
Results of the component inspections are documented in accordance with Data Sheet #14.
During unit outages or valve inspections, a fiber-optic visual inspection of the HP first stage and
IP first stage stationary and rotating elements should be performed to check their current
condition. In addition, an inspection should be performed of the discharge side of the last stage
blading in both the HP and IP sections. Perform a visual inspection of the LP turbine last stage
buckets (LSB), and note their condition. On either fossil or nuclear units, access ports may be
available at other LP locations also to make similar visual inspections. If access ports are not
available, plants should consider a plan to install them as part of the work scope during
upcoming major outages.
Cracking on the blade airfoil, roots, disk steeples, lashing lugs, shrouds, or erosion shields
requires immediate attention to preclude the possibility of an operating failure.
Significant erosion to the inlet edge of the last stage LP turbine blade can indicate water level
problems in the neck heaters or moisture removal drains. Such problems should be immediately
corrected. LP moisture removal drains can be inspected only during a planned section overhaul.
Foreign object damage to any blades should be noted because this may be due to loss of rotating
components during unit operation. The accumulation of deposits should also be noted.
On some blades with historical cracking problems, it may be necessary to perform a limited
florescent penetrant or eddy current inspection to search for cracks in locations where they have
been previously found.
During an outage, perform a crawl-through inspection of the generator and evaluate the visual
condition of the windings, retaining rings, through bolts, and blocking, and note the conditions.
Inspect the collector rings and brushes for wear, grooving, and vibration, and note the conditions.
Visual inspection should be done after a transient disturbance, such as a short circuit or out-of-
phase synchronization.
Early signs of a loose or vibrating end winding are dusting or greasing. Dusting consists of
visible deposits of a fine power, found on the coils as they exit the core, near coil-to-coil tie
wraps or on coils next to wedgings and blocking.

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Greasing is the same powder mixed with oil that was able to enter the generator. Oil can become
deposited throughout the windings either through a malfunction of the seal oil system or by
gradual entrainment of oil in the hydrogen gas due to a low purity situation.
Visual inspections may also reveal obvious signs of girth cracking that is present in the coils
ground wall insulation as the coil exits the stator core.
A partial listing of EPRI published research related to the in situ visual inspection of turbine-
generator components is as follows (organized by year of publication):
Interim Guidelines for In-Situ Inspection and Monitoring Techniques for Steam Turbines:
Volume 1: An Overview of Remote Visual Inspection, EPRI, Palo Alto CA: 1999. TR-
113996-V1.
Interim Guidelines for In Situ Visual Inspection of Inlet and Outlet Turbine Stages: Parts 1 &
2, EPRI, Palo Alto CA: 1999. TR-114961.
Demonstration of a Video Probe Delivery Device for In Situ Inspection of Steam Turbine and
Combustion Turbine Machines, EPRI, Palo Alto CA: 2002. 1004002.
1.5.15 Out-of-Limit Conditions and Upsets
Out-of-limit upsets or other operating mishaps may be isolated incidents of limited consequence
or an early warning of a potentially significant problem that may impact future unit reliability
and result in a premature unit major overhaul. This portion of the condition assessment is meant
to provide a backup for the more extensive audits and interviews previously discussed for the
major systems and components.
Data Sheet #15 itemizes the most common problems that can manifest themselves on a unit. For
each item, the assessor is to specify when the problem occurred, how many times, and what
action was taken by operations or maintenance. The assessor is then requested to make an initial
determination as to whether it is likely to have a significant impact on turbine-generator
reliability, and if so, rank the potential as low, medium, or high.
As further guidance, it should be noted that this part of the assessment is limited primarily to
identifying the occurrence of events or problems that have been known to affect turbine-
generator systems. Further determination as to their source or root cause would be performed in
the more comprehensive evaluations of individual systems and components. Therefore, the
results of the out-of-limit condition assessment are most likely to provide the basis for issues that
are color-coded as blue in the summary report (where the recommended action is to monitor the
issue more closely until a more specific diagnosis is possible).

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1.5.16 Review/Update Turbine Generator Maintenance Plans
Data Sheet #16 complements the maintenance history summary on the turbine-generator
components and systems prepared at the start of the assessment (Data Sheet #1). This portion of
the condition assessment provides a supplemental record for each system or component, where a
record is compiled of the date of last inspection, the date of next inspection, and comments as to
the ability to run until the next inspection of each component and system, based on the results of
the condition assessment performed.
From this comprehensive record, the final overall condition assessment is summarized on Data
Sheet #17. The process of using the information that has been gathered to make this overall
assessment is discussed next.
1.6 Evaluating Situations and Making Recommendations
To complete a condition assessment report, the results from the previous data sheets are (1)
assembled into a package of reference documentation, (2) consolidated onto a single summary
sheet, and (3) individually evaluated in terms of the need for action based on the perceived risks
involved.
Item 3 uses a summary table (Data Sheet #17) that divides the turbine-generator into the major
systems or components that were individually examined. The most critical finding associated
with each is identified. To complete the report, the engineer or person responsible for the unit
assessment must further indicate the severity or immediate need for action by means of a color
code.
As previously noted, this final step in the overall assessment procedure is specifically designed
so that once the evaluation process is complete, there is only one of three possible outcomes
recommended for the systems, sections, or components involved.
1.7 Condition Assessment Example
Table 1-7 presents an example of the summary documentation produced by a turbine-generator
condition assessment, using the format provided in Data Sheet #17. In the example, 13 systems
and components are identified. The first seven provide an update on the status for the major
components that form the turbine-generator system, for example, the five turbine subsections, the
generator, and the exciter. The remaining six reflect the current status of the support systems
involving lubrication, seals, controls, and monitoring instrumentation. A color code is used in the
example in Table 1-7 to denote the level of component degradation and degree of urgency
required in corrective action.
As indicated by their green color-coding, the three LP turbines are considered to be in good to
excellent condition. In essence, this may be interpreted that no perceptible symptoms, indicators,
evidence, or warnings were identified from the audit and interview that indicated that their
condition had changed in any significant or noticeable manner since the last assessment. The

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possibility of recommending the scheduled maintenance be extended would be based on how far
into their interval the assessment had been made.
If this assessment were completed only six months after the most recent maintenance performed
on the section, it would be premature to make a recommendation to extend the current
maintenance interval. Conversely, if the reported condition had remained stable over an extended
period of several years, this would be worth noting since deferring the scheduled maintenance
could save significant maintenance costs and possibly be adopted by management if the risks of
deferred maintenance associated with these sections were assessed as low. Because such a
recommendation would involve significant savings, the audit and interview attached to the
summary would be relied upon as a basis for such a consequential decision.
In the example, both the HP and IP turbines are reported as showing signs of degradation in their
performance. The data sheets associated with performance (#4) would provide the
documentation supporting this observation in terms of the measured values. The recommended
action (color coded blue) is a consequence of the expert/specialist interview. From the interview,
it was noted that the percentage of change in the performance and timing suggested that a
problem was appearing, but that the rate of degradation was not sufficiently rapid to warrant
immediate or intermediate attention.
The blue color code indicates that the condition of a particular system or component is changing
enough to take notice, but that the specific root cause or component has yet to be clearly
identified. Referring back to Table 1-6, eleven potential causes are noted in which a decrease in
HP performance is the consequence. In this example, the blue code indicates that insufficient
information has been collected and examined to make a more precise determination. The
reasonable and appropriate action is therefore to monitor it until a more definitive assessment is
possible.

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Table 1-7
Example of Overall Unit Condition Assessment
Plant and Unit Number: Any Plant #1
Unit OEM: GE Date of Assessment: 9/1/04
Design Rating: (MW): 500 Date Last Inspected: 1/1/00
Unit Maximum Dependable Capacity: (MW): 490 Commercial Operation: 12/15/80
CONDITION ASSESSMENT SUMMARY
DEGRADATION Component or
System
Severe Significant Some
Good
Condition
Comments
HP X Performance down 1% -
monitor.
IP X Performance down 1.5% -
monitor.
LPA X
LPB X
LPC X
Generator X End windings may be loose.
Vibration data has not been
consistent.
Exciter X Exciter needs balancing.
Insulation is very low on bearing.
Lubricating Oil
System
X Particle count far exceeds specs
Seal Oil System X Vacuum values trending toward
higher end of acceptable criteria
Controls X Overspeed trip too high. CV
crack and intercept points need
adjustment.
EHC/MHC System X Chloride count trending toward
higher end of acceptable ppm.
Valves X Control valves and main stop
valves are sticky. Last inspected
three years ago.
TSI Instrumentation X
Recommendations:
Both the lubricating oil and valves require Immediate attention. Refer to Data Sheets #5 and #7 for details.
Based on their condition, the unit needs a weekend shutdown as soon as possible to correct these
potentially serious problems. Work is also required on the exciter and turbine controls. Refer to sheets
#12 and #13 for details. The urgency is not immediate, but this will require action before the currently
scheduled intervals listed for these systems. Refer to sheet #16 for the current schedule of maintenance.

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With regard to the generator, seal oil system, and EHC/MHC systems, the same situation applies.
Some degradation was noted in the measurements. Similar to the HP and IP turbines, the color
code reflects that early indicators had been noted but that it was not possible to conclusively
identify the cause at this time. In the case of end winding vibration, it is noted at the time that the
readings may be suspect because of noted inconsistencies and the inability to get repeatable
results.
The transition from a suspected to a more conclusive identification of the problem is noted on
both the exciter and the turbine controls. Color-coded as yellow, the need for balancing and
insulation replacement on the exciter is explicitly recommended. For the controls, the overspeed
trip and the control valve intercept points need to be readjusted. Yellow indicates that these
actions do not immediately threaten the reliability or health of the unit but that action should be
taken at the next unit outage opportunity.
Two components, the lubricating oil system and valves, are highlighted as condition red,
meaning that, as a consequence of the assessment, there is a considerable risk to the unit based
on the present condition of these systems. In the case of the lubricating oil, the particle count far
exceeds recommended limits. At best, this could cause significant damage to the bearings. At
worst, the breakdown of a bearing could damage the entire rotor system.
The previous condition assessment on these two systems would also play a role in determining if
this was a change in the severity level for a problem previously noted or if this was the first time
the problem was reported. Presuming that the condition assessment on the lubrication system had
been performed regularly, a change in color from yellow to red would indicate a steadily
deteriorating situation. Based on the earlier report, provisions should have been made to flush,
filter, and replace the oil. However, if the problem was not apparent before this report, this
indicates that the change in particle count was sudden and the risk of an in-service breakdown
was even more imminent. In the case of the control and main stop valves, the principal reason
given for immediate correction is the fact that their last inspection was over three years ago,
based on the record assembled in data sheet #1.
Note that assigning urgency to the issue is in part a reflection of the degree of precision that the
assessment can provide. Any problem that is assigned a code that requires intermediate or
immediate action generally should have sufficient supporting data to make an informed opinion
as to the root cause of the problem. If the assessor cannot make this determination, then a blue
condition would be more appropriate until more information can be gathered.
The exception to this rule would be a situation in which a sudden or abrupt change occurred
and/or one or more of the indicators began to degrade rapidly. Any abrupt or abnormal
conditions should have been identified on data sheet #15, where a range of symptoms are
itemized in which alarms were tripped or normal operating parameters were exceeded.
For example, a sudden step change in vibration that could be attributable to a loss of a cover or
blade tip might warrant immediate action even though there had been no early warning of the
problem or the present level of increased vibration appeared stabilized. The potential
consequence of losing more covers or even blade sections outweighs the need to proceed with a
deliberate plan of corrective action.

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1.8 Summary Remarks
Two common reasons why a plant does not follow best maintenance practices are cited as (1) the
maintenance is totally reactive, and (2) management has not defined the rules of conduct to
achieve the best maintenance practices that are possible.
The major emphasis for performing an in-service condition assessment is to adopt a proactive
approach. In this approach, a systematic examination of key indicators is assembled and
supplemented by interviews with specialists/experts. The team assigned responsibility for
conducting the assessment understands that beginning this process demands that they produce
one of three outcomes regarding recommendations for the systems, sections, or components that
form the unit. The data collected within the assessment report format is specifically directed to
support the formation of an informed decision. A summary of periodic recordings and
measurements are maintained to signify trends or changes. Interviews provide the opportunity to
solicit opinions from those who are most familiar with the particular system. A checklist of
abrupt events provides a further catchall to note issues or problems that may or may not prove
significant but should not be ignored since historically they have proven to be signs or symptoms
of reliability problems for steam turbine-generator units.
Critical to the success of the assessment is the formation of a team that is empowered both with
the authority and budget to meet with the respective specialists and allow the report to be
periodically updated. As noted, a baseline assessment should be conducted as soon as practical
after a major overhaul to provide the optimum benchmark for subsequent comparison and
evaluation. The next assessment should be considered at mid-cycle from the next scheduled
major inspection. The frequency of the inspection interval after this should depend upon the
findings of the first condition assessment.
In completing the report, it should be emphasized to the team that the opinions and
recommendations offered in the summary are expected to be subjective to some degree. Because
this assessment relies on on-line data available at different points within the overall system, the
recommendations are based on the perceived condition, rather than what an inspection during a
shutdown may reveal to be the actual, absolute status of the unit health. The team should
recognize this when it is formed so that an unreasonable demand for 100% certainty does not
inhibit the assessments of risk and need for action that are required for each major system. If the
team is not allowed certain latitude to speculate based on the evidence at hand, then the process
will be compromised.
So as not to exaggerate or overstate the perceived condition of any given system, a general rule
of thumb is applied to rate the degradation as it proceeds from some to severe. Some
degradation is identified by a change in one or more data points that is notable but not
necessarily an early indication of an impending breakdown. As a condition progressively
registers significant or severe in concert with this appraisal, there should be an attempt by
the team to specify the suspected root causes and the corrective action that would be required,
assuming the diagnosis is correct.

1-53
At this point, management can proceed to either follow the recommendation or invest additional
resources in analysis or testing to verify the condition. This is considered to be the break point
where in-service condition assessment transitions to life cycle management. If a problem
identified in the assessment were particularly significant (such as a potential for a catastrophic
failure or breakdown of a major component that would require a major outage to correct), a more
involved decision process would be required. This process would evaluate strategies of whether
to seek a repair, replace the system in kind, or seek a new/upgraded design. Results from the
condition assessment would provide input to this process in terms of details on the history,
frequency, and urgency of the system or component under scrutiny. Should the life cycle
management team decide to replace or upgrade a system or component, the process would come
full circle because this action would be noted in the first data sheets of the condition assessment
on the replaced/upgraded system or component.

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2
PRE-OUTAGE PLANNING AND BIDDING
Traditional methods of turbine-generator outage planning have focused on the speed of repair,
that is, planning outage scopes and managing vendors to speed up the open-repair-close cycle of
the machine. With the continuing pressure to reduce outage duration, the temptation is to reduce
scope and not repair the machine. The initial portion of this guideline, associated with pre-
outage planning in the context of general outage practices, deals with the engineers
responsibility to play a greater role in defining reasonable expectations of technical support to
meet different scopes of work envisioned by a plant. A basic element in such planning is how to
reach outage duration or O&M budget goals by means of shorter outages. Pre-outage bidding,
particularly from third-party suppliers, offers a sizable potential return in both reduced downtime
and direct costs if reliable replacement parts can be negotiated and secured prior to when the
teardown begins.
This section of the guidelines is divided into steps that are organized in a sequence that begins
when the tentative scope of maintenance is first proposed and ends when the unit is actually
returned to service. The information contained within this volume of the guidelines is designed
to assist a turbine engineer anticipate, identify, and recommend reasonable expectations of
technical support that meet different scopes of work envisioned by a plant.
After the scope of maintenance has been established, this volume provides an approach to pre-
bid critical components using the repair/replacement criteria compiled in Volume 2. A way to
identify, arrange, and monitor the involvement of outside sources of specialized support is also
addressed as an activity within the pre-outage planning phase. This volume of the guidelines
concludes with a review and discussion of the basic procedures and plans that should be in place
before the next phase of the outage (disassembly) begins.
Appendix B provides a complete turbine-generator outage report template. The basic principle
behind this formatted template is to provide the user with a way to complete the report as an
outage progresses. If updated on a daily basis, the outage report should be basically complete at
the end of the job except for minor clerical details. Appendix C includes over 155 data reporting
sheets to supplement the various component- or system-related activities addressed within the
outage report. An index of the information organized within the turbine-generator outage report
is shown in Table 2-1.

Pre-Outage Planning and Bidding
2-2
Table 2-1
Index to Turbine Outage Report: Appendices B and C
Section Appendix B Table of Contents
I Introduction
II Name Plate Rating
III Outage Personnel
IV Summary of Recommendations V. Work Summary
V Work Summary A. HP Turbine
VI Data Sheets B. IP Turbine
VII Test Data C. LP Turbine
VIII Photos D. Generator
IX Appendix E. Exciter
X Contractor Reports F. Valves
G. Other
Section Appendix C Table of Contents Sheet Numbers
I Turbine Axial/Radial Clearances, Alignment and Position 1 27
II Turbine Bearings, Journals, Oil Seals, Rings, and Coupling Data 28 56
III Cylinders, Shells, Rotors and Blade Ring Dimensional Data 57 71
IV Controls and Front Standard Mechanisms 72 93
V Oil Pumps 94 99
VI Main Turbine Valves 100 126
VII Generator Exciter 127 150
VIII Protective Devices and Pre-Operational Checks 151 153
IX Vibration and Balance 154 155

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2.1 Identifying and Establishing Engineering Responsibilities
A utility engineers involvement in any maintenance outage may range from preparation and
cursory overview to outage management and technical direction. The utilitys philosophy and the
engineers skill and experience levels will ultimately be a factor in the role the engineer will play
before, during, and after the outage. To be an effective participant, a turbine-generator engineer
must have or must gain a basic understanding of the turbine and generator mechanical, electrical,
and thermodynamic processes involved with the operation and maintenance of the turbine and
generator. An understanding of machine function, operation, and repair is demonstrated by the
variety of potential activities to which the engineer may expect or be asked to contribute:
Developing work packages - before and during overhauls to support inspections, repairs, and
other activities
Assessing stocking levels and alternative approaches
Reviewing historical purchases
Assessing parts requirements for upcoming overhauls
Monitoring procurement process with key inspections
Integrating receipt of components/parts with outage and overhaul planning
Evaluating vendors and bids
Assessing current condition of components
Performing visual inspections and nondestructive evaluation
Comparing the current machine condition with historical records
Maintaining the number and types of failures
Maintaining historical records and evaluating data
Providing problem resolutions
Accessing and examining procedures
Preparing functional procedures including drawings
Creating and reviewing repair procedures
Monitoring repairs: costs, time, efficiency, and effectiveness
Interfacing with OEM and non-OEM personnel
Assisting in startup functions
Evaluating repair/overhaul frequency
A utilitys style of turbine and generator maintenance may place an increased emphasis on
maintaining constant attention on current machine conditions and future needs. This requires
concentrated preparation, effort during turbine outages, and focused outage follow-up. The
responsible engineer, therefore, requires a well-rounded background to meet the demanding and
changing maintenance environment. As an introduction to and reference source for the current
state of knowledge associated with the turbine steam path and damage in steam turbines,
engineers should start with the two-volume EPRI report Turbine Steam Path Damage: Theory

2-4
and Practice, TR-108943-V1 and V2 [1]. The volumes represent an integration of the work
performed and reported by researchers, designers, and turbine operators spanning the twentieth
century, with emphasis on the last 20 years. In particular, data offered in this compilation can
provide the engineer with a basis of accepted industry standards on which to formulate and
support specific recommendations.
2.1.1 Engineering Responsibilities in a Major Outage Work Scope
The plant engineer should plan support for an outage work scope as three distinct phases of
activities:
Pre-outage
Outage
Post-outage
Each phase requires unique but interrelated activities. As an example, the pre-outage plan
implemented during the outage should automatically require a post-outage review to re-evaluate
it from both its technical and economic merit. It is recommended that technical merit be
measured in terms of improved machine function or performance, and the economic merit can be
measured in terms of schedule or economic impact.
2.1.1.1 Pre-Outage Activities
As shown in Figure 2-1, the pre-outage planning and preparation can begin in May of one year
for an outage beginning in February of the next year. Engineering involvement crosses each one
of the areas listed and may extend from an advisor or a consultant capacity in some areas to
direction and responsibility in others. It is not unrealistic for a single major outage to involve
more than 750 engineering work force hours in turbine and generator outage planning and
preparation.
Based on all the databases and plant information used to develop a plan for an outage, the
maintenance plan is evolving from a time-based or reliability-centered approach to one based on
financial risk. This method optimizes operations and maintenance expenditures over the entire
plant or system. EPRI software (Turbo-X, 1001074) has been developed that provides a powerful
planning tool for engineers to use in evaluating specific proposals for deferred maintenance
options. The program provides maintenance interval planning that is based on financial risk
assessment and component reliability data.
Through an industry survey, general turbine-generator outage information was obtained by EPRI
in early 2005. The survey asked various questions relating to five major areas concerning T-G
outages: general unit information, outage scope, outage interval, outage length, and labor source.
Responses were received from 13 utilities encompassing 103 units from approximately 40 plants.
The units included both fossil and nuclear plants and ranged in unit size from 201350 MW. The
goal of the survey was to provide outage planners with general T-G outage intervals and
practices of other utilities and plants. A summary of the compiled results follows.

2-5
General unit information:
63 of the 103 units are GE:
43 are 40 years old.
28 of the 103 Units are SW:
10 of the 103 units are Alstom, ABB, or Hitachi.
16 of the 103 units are nuclear.
47 of the 103 units are load following, subcritical, and tandem.
15 of the 103 units are base load, supercritical, and non-nuclear.
Outage scope information (out of 103 units):
38 perform full-train outages for turbine, generator, and valves.
16 perform partial outages for turbine, full for generator, and partial for valves.
51 perform partial outages on valves.
18 try to shorten outages by having spare parts.
39 have spare journal or thrust bearing components.
57 have spare valve stem and disc assemblies.
88 have made changes to improve work execution during turbine/generator/valve outages
including the use of racks, rollers, valve maintenance guides, and so on.
Outage interval information (out of 103 units):
52 determine outage intervals based completely on calendar time.
12 determine outage intervals based completely on refueling.
29 determine outage intervals based on operating hours and starts.
58 have outage intervals of < 10 years for turbine sections.
81 have outage intervals of 6 years for valves.
78 conduct detailed outage planning at least 1 year in advance.
29 conduct detailed outage planning 2 years in advance.

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Outage length information (out of 103 units):
32 have 6 week outages for turbine sections.
92 have 10 week outages for turbine sections.
71 have 2 week outages for valves.
5 have strict outage work weeks of 20 hours/day, 6 days/week.
72 have outage work weeks of 20 hrs/day, 6 days/week but alter this to 24/7 outage coverage
at the beginning and/or end of an outage.
29 have the turbine-generator outage as the critical path item for the outage.
55 have the boiler as the critical path for the outage half or all the time.
Labor source information (out of 103 units):
59 have a combination of plant/utility/contractor/OEM for turbine/generator/valve craft
labor.
20 have solely contractors for turbine/generator/valve craft labor.
23 have solely plant staff as turbine/generator/valve craft labor (all from the same utility).
55 have utility supervision of the turbine/generator/valve craft labor.
34 have plant project management of turbine/generator/valve component.
58 have utility project management of turbine/generator/valve component.
17 have contractor/OEM technical direction for turbine/generator/valve components.
52 have utility technical direction for turbine/generator/valve components.
53 contract for specialty labor including NDE, sandblasting, scaffolding, and induction
heating.
67 have craft labor of classification including millwrights, mechanics, carpenters, scaffolders,
machinists, and pipe fitters.
66 have crews within their utility dedicated to turbine/generator/valve work and repair.

2-7

Figure 2-1
Example of an Outage Plan

2-8
A recommended pre-outage work scope checklist of activities is presented in Table 2-2.
Table 2-2
Checklist of Pre-Outage Activities
Agenda Action Item Subsystem
1. Recommendations Stationary components Steam path and shells
Rotating components Steam path and rotors
Sealing areas
Valves
Auxiliary equipment
Controls
Operation history
2. Planning Budget
Work packages
Parts
Services
Laydown plan
3. Scheduling Sequencing
4. Procurement Specifications Diaphragm, buckets, bearings, oil deflectors
Services Vendor resources, blanket purchase orders
5. Maintenance Manpower resources Quantity, craft mix
Equipment resources
Training
6. Performance
assessment
Outage activities Condition assessment, corrective actions,
job management, vendor/contract
administration
Post-outage activities Performance
Pre-outage activities include a review of at least the most recent past outage reports,
recommendations (including OEM-initiated recommendations), and operating conditions to
determine the expected machine condition and repair requirements. Outage reports should
contain machine condition, condition assessments, and recommendations from each area of
outage activity including:
Disassembly and reassembly
Opening and closing clearances including alignments
Stationary and rotating components
Valves
Auxiliary equipment

2-9
At a minimum, these reports should include an evaluation of what was found, what was done,
and what is expected in the future. Condition assessment and outage action may be documented
in a variety of electronic formats as well as hard copy. Electronic formats may most easily
transcend the intervals between outages. Using commercially available applications
(spreadsheets, databases, and word processors) may provide a measure of protection against
software obsolescence and issues with future data exchange. Either hard copy or electronic
format should be supplemented with photographs. Both methods of record keeping require a
method to log, document, and summarize the results for ease of coordination, review, and
monitoring. Outage recommendations and follow-up activities are easily managed in a database
that would include, as a minimum, the following inputs:
Event
Event date
Type of event (major outage, forced outage, pre-outage or post outage meeting)
Discussion or description of the condition
Recommendation
Response to the recommendation
Action required
Assignments
Required completion date
The information provided within the recommendation section of the database may easily
supplement or complement a full-scale maintenance management system (MMS).
Depending on the size of the utility and functional structure, a review of outage
recommendations will result in task assignments to both the engineer and other resources. Those
other resources may include maintenance, procurement, or planning. The plant engineer will be
required to develop specifications for use with procurement of materials, repairs, and vendor
support. The engineer will also be required to develop work packages to accomplish the
in-house support activities. A work package may be either a simple process instruction or a
detailed work plan.
A process instruction sheet is an easy tool to use during an outage when communication to other
internal resources, such as a machine shop, is required. A process instruction sheet can be used in
either electronic or hard copy format.
A detailed work package would normally be prepared before an outage. However, the work
package format is still usable during an outage to provide repair instructions after disposition of a
finding.
Information that should be included in either is itemized in Table 2-3.

2-10
Table 2-3
Recommended Process Instruction Sheet and Detailed Work Package Information
Process Instruction Sheet Detailed Work Package
Contact person to answer questions Descriptive title
Shift and extension of contact person Scope Intended use
Time and date of submission - Generic application
Component identification - Specific application
Request return date and time Support required
Work completed by contact person - Craft resources
Description of what must be done including - Parts or materials
- Material requirements Processing instructions
- Dimensional tolerances Tracking Information
- Description of action required - Unit or equipment assignment
Sketch - MMS identifier
- Prepared by
- Preparation date
Activity instructions
- Sketches
- Sequence of activities
- Material requirements or alternatives
Pre-outage activities also include a review of part requirements. Stand-alone or integrated
commercially available software is a vital tool for this activity. Use of a database will allow
searching, querying, and displaying part information for both pre-outage evaluation and part
selection during an outage. Information may be reviewed live through the utilitys
warehousing database or as a snapshot. A snapshot allows independent review and
manipulation of data independent from live information. The parts database may include all
information about parts that are available for use. The database can include parts not currently
stocked but provide ordering information.
Complementing a database of part information is a database of part use. The part information
database provides all the information unique to a part. The part use database provides all the
locations where a part is used. The database is updated to reflect changes in part application
requirements or modifications for a specific location.
Recommended information to maintain on a parts database and a database of part use is
summarized in Table 2-4.

2-11
Table 2-4
Recommended Information for Parts and Part Use Databases
Parts Database Part Use Database
Part identifier Part identifier
- Stock number - Stock number
- Part number - Part number
Part description Unit application
Alternate or superseded information Location grouping or identifier(s)
Stocking level - Descriptive
Quantity available - Numeric
Date of last update Part name
History of usage Location description
Purpose of information Location
- Stocking Quantity used at location
- Ordering but not stocking Visual representation of location of use
- Refurbishment Link to part information database
Comments
Action items
Visual representation of part
The part use database may also provide a shopping list of parts by including an available/non-
available field in a database table. Parts needed may be identified automatically, grouped and
sorted, and printed out during either pre-outage activities or the outage.
2.1.1.2 Outage Activities
The outage work scope begins to take shape after the recommendation review and work package
creation. Recommendation-driven services for outage activities can then be identified. Selection
of in-house capability or vendor resources is determined. The outage budget is often outlined
much further in advance than the preceding outage year. But after the work scope is developed,
definition and refinement of the budget can take place. Procurement can begin to secure vendor
support and lock in resources months before the outage. Often, the availability of the specialized
turbine repair resources is limited, and reserving their services should be done as far ahead as
possible (at least four to six months in advance).
Two other derivatives of pre-outage planning should be schedule development and turbine deck
work flow. The schedule development is impacted by the sequence of disassembly necessary to
accomplish the known repairs within the outage duration. The turbine deck lay-down plan is
reviewed and modified to support repair activities.

2-12
Maintenance work force resources are determined from scope of work, budget constraints, and
the scheduled outage duration. Pre-outage training is a useful tool most effectively completed
just before an outage. Training can be focused into a number of areas:
Work scope presentation and review
Turbine and generator assembly/disassembly sequence
Turbine and generator maintenance procedures
Terminology
Procedures
Readings and documentation
Figure 2-2 represents a typical spread of engineer-supported outage activities.

2-13

Figure 2-2
Sample of Engineering-Supported Activities

2-14
Plant engineering provides both pre-outage support and real-time outage support. The amount of
pre-planning dictates the workload during the outage, allowing time to handle other outage
issues. Non-emergency areas that may be covered during an outage are as follows:
Component inspection
NDE finding disposition
Component condition assessment
Corrective action evaluation
Repair evaluations
Timekeeping and schedule reporting for vendor activities
Job management
Problem resolution (both technical and personnel)
Repair direction
Vendor surveillance
Vendor/contact administration
Startup
2.1.1.3 Post-Outage Activities
Post-outage activities are a reflection of the pre-outage preparation. The purpose of post-outage
activities is to review outage documentation and disseminate the information for appropriate
future action. A list of post-outage documentation and action requirements or purposes is shown
in Table 2-5.

2-15
Table 2-5
Post-Outage Activities
Documentation Action/Purpose
Outage dates Log actual outage date
Photos Sort and file for documentation
Files Disseminate and update miscellaneous data
Review work package information and update file version
Diaphragm QA Review outage report and log repair recommendations
Bearings Log repairs, create repair reports and update bearing repair
specification (as required)
Buckets Review repair times and update repair history
Create repair reports, log measurements and update File
L-0 and L-1 pins Update replacement location and size history
Diaphragms Review repair times and update repair history, area checks, etc.
Create repair reports and modify diaphragm repair specification as
required
Boresonics Review reports and update inspection history
Studs Update stretching/replacement history
Main steam lead flange Check thickness
Piping inspection report Review reports and update inspection history
IP rotor run outs Review reports and update inspection history
Startup document Review and update
Turbine deck layout Update layout plan
Repair of removed parts Spares: diaphragms, double flows, nozzle box, valve components
Miscellaneous Outage assessments, recommendations, and parts (needs, changes,
description, updates, stocking levels, etc.)
Post-Outage Meeting
Post-outage meetings should be conducted within a reasonable time (four-to-six weeks)
following the outage. The post-outage meeting distance in time from the outage is a balance
between documentation review and outage personnel availability. Documentation prepared for
the post-outage meeting should include:
Recommendations entered into review format (for example, databases)
Work force expenditures
Parts
Budget
Lessons learned

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Attendees at the post-outage meeting should include:
Turbine and generator outage supervisors
Turbine and generator foremen
Utility turbine and generator engineers
Turbine-generator planner
Outage vendors (as applicable)
2.1.2 Methods to Estimate Engineering Resources and Work Force Required
In order to identify the engineering resources required to support a turbine-generator outage, the
direction or philosophy of what is to be accomplished must be identified. The following are
examples of turbine maintenance philosophy statements:
Turbine and generator overhaul maintenance is performed 24 hours a day, 7 days a week.
This means each maintenance shift is staffed and responsible for doing an even split of the
overhaul work scope. Therefore, each shift requires all elements of support. Engineering
support is provided by whatever means necessary to the turbine maintenance overhaul crews
to meet their direction.
Equipment is maintained in a manner that will restore the equipment to at least the quality
standard to which it was originally designed and, where appropriate, based on experience, it
will be rebuilt to a higher quality standard. Under no circumstances is the quality standard to
be reduced. Therefore, engineering support is provided as appropriate to the turbine overhaul
to meet equipment needs.
Turbine-generator outage activities can be grouped into the following major areas:
1. Preparation
2. Shutdown
3. Turbine disassembly and clearance documentation
4. Component inspection
5. Component repair
6. Turbine reassembly, alignment, and clearance documentation
7. Startup
8. Review

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The scope of activities within each grouping is defined by what must be accomplished and
should be consistent with, but independent of, the application of resources. The distribution of
responsibilities within each grouping is adjusted to meet the utilitys resources and turbine-
generator maintenance philosophy. For example, turbine disassembly requires:
Knowledge of how the turbine-generator is put together
Knowledge of the best direction for disassembly to meet the repair plan
Knowledge of what readings are necessary to evaluate the machine condition
Knowledge of what readings are necessary to reassemble the turbine
The utilitys engineer, the OEM engineer, the vendor engineer, or utility maintenance resources
can perform these functions.
2.1.3 Tasks Deferred to Reduce the Scope and the Potential Implications
Absorption, consolidation, and redistribution of activities are methods used to reduce turbine
engineering support scope. There are additional resources, such as OEM engineers, utility
maintenance and planning, and vendors, in addition to turbine engineering that can be included
to accomplish the activities and tasks of pre-outage planning. Each resource may be able toin
part or in combination with othersprovide the necessary technical and cohesive interaction for
a successful outage. But it should be noted that nothing comes without a cost. The level of
focused continuity maintained where additional resources are planned to be used will be
consistent with the involvement allowed to turbine engineering as overseer and coordinator of
this support.
Standardization of practices, record keeping, electronic interface, and electronic data storage are
methods of reducing activity involvement without losing continuity. Data recording and retrieval
become essential when interaction is reduced. One way to reduce activity support requirements is
to reduce data and information handling, retrieving, and processing time.
The advantages of maintaining the knowledge or historical database directly complement the
ability to plan an outage and quickly retrieve and apply information during an outage.
Engineering support scope is reduced through shared and distributed information resources,
which can be retrieved and used by others. Personnel that are not reasonably familiar with the
database are slowed during outages and lose their effectiveness.
2.1.4 Tools Available and Input Needed to Define Tasks for a Scope of Work
One of the best tools available to a utility is its own activity history. Utilization of relevant
history incorporates the utility nuances into the resource identification and estimation process.
This information is typically available through an MMS or other record keeping method.
Non-MMS tools available are spreadsheets and databases. These can be maintained as individual
records or group or department entries. The important message is to begin. Too many times,

2-18
critical knowledge is maintained by an individuals memories, notes, or recollections. When
these individuals leave, retire, or are promoted, their wealth of recollection is lost.
Essential information to log for future reference is:
System
Scope
Duration
Description of activities performed
Standard industry practices are a starting place if no information is available within the utility.
Information may be obtained through other sources such as EPRI, utility contacts, or vendor
contacts to form a basis against which in-house details are compared.
2.2 Pre-Bidding and Procuring Parts or Services (When Scope Is Defined)
Preparation to purchase either services or parts requires the same two fundamental items:
Defining what is needed
Identifying when it is needed
Included with each of these items are the details of what it looks like, how many are required,
how it is obtained, and what method of payment will be used. These details develop, shape, and
become the specific elements of the purchase as the type of purchase is defined. Specific
guidance is provided in Volume 4 for the procurement of turbine-generator components such as
blade rows, HP/IP/LP turbines, and generator rotors for both fossil and nuclear units as well as a
generator rotor rewind specification. The guidelines address very specific issues associated with
the purchase of these expensive components. They also provide advice regarding critical issues
such as warranty, liquidated damages, information needs, and other issues that may be important
to a specific plant.
Part purchasing requires identifying two essential items that will help ensure that the right part is
ordered, received, and purchased. The two items are:
The part geometry
The materials
The pitfalls of purchasing parts may seem obvious, but far too often they put a snag in the best of
outage plans. For example, a part is ordered that is identified with a geometry description of 1"
(2.54 cm) pipe and made from stainless steel (SS) material. The item could be received matching
the outside dimensional requirements of 1" (2.54 cm) pipe (manufactured to National Pipe
Standards [NPS]), but the wall thickness could be anything. The material could be any of the
austenitic, ferritic, or martensitic stainless steels but would probably be the cheapest of the three.
The received replacement part probably would not meet the desired functional requirements, and
the inappropriateness would most likely be discovered during the repair process. Either the

2-19
serviceability of the replacement part has to be evaluated, or the part must be returned and
replaced within the outage duration.
Unlike part purchasing which deals only with parts, services purchasing is defined as containing
the services of people and may include activities such as consulting, technical direction, or on-
site repairs. They may also include parts, but the primary thrust is services provided. A list of
information recommended for parts and services purchasing documents is presented in
Table 2-6.
Table 2-6
Recommended Parts Purchase Document Information
Parts Purchasing Document Services Purchasing Document
Nontechnical description of the item Nontechnical description of the scope of service
Technical description of the item, as
appropriate
Schedule
Part use and location information Definitions, as appropriate
Quantity of items required Material requirements
If a first time purchase, describe the
material/geometry
Service requirements
If a repetitive purchase, specify the
appropriate part number
Inspections
Special handling: packaging, in-transit
protection
Quality assurance
Delivery instructions: carrier (as appropriate),
transportation, location, time of day
Reporting requirements
Mobilization and demobilization requirements
Living expenses scope
Schedule
Form of proposal
2.2.1 Stationary Repairs - Diaphragms, Packing Rings, and Sealing Strips
Damage occurs to the diaphragm steam path and body (structure) in service that must be repaired
during outages. The degree and location of damage varies depending on steam conditions and
position within the steam path. The following is typical of the type of damage that might be
evaluated and repaired during an outage:
Foreign object damage (FOD)
Solid particle erosion
Water/steam erosion
Chemical attack
Packing and spill strip hook fit damage

2-20
Integral spill strip damage
Thermal/pressure distortion dishing/out of round
Fretting on loaded surfaces
Cracking
Failed welds
Two basic items are required to pre-bid steam path stationary (diaphragm) repairs to both the
steam path and structure:
Repair procedures with either the work scope definition or the anticipated work scope
A standard by which to evaluate the bids
Examples of repair procedures are found in Volume 2. In general, it is recommended that any
repair procedure include the items listed in Table 2-7.
Table 2-7
Recommended Diaphragm Repair Purchase Document Information
Item Subsection
Work scope
Process definitions Major repairs, layout procedures, measurements,
sidewall repairs, partition repairs, horizontal joint
repairs, minor repairs, process deviations
Quality assurance
Nondestructive tests
Tolerances Partition shape, area, dimensional
Partition dimensional data sheets Area checks, diaphragm checks
Diaphragm inspection requirements

A diaphragm repair procedure contains certain essential variables. If the repair involves using a
filler material of 410 stainless steel, a stress relief procedure is required after repair; a diaphragm
repair using an Inconel filler material does not require this.
Partition shape information should be either reverse engineered during the repair or provided
within the repair procedure. Partition shape tolerances and dimension data sheets are important to
achieve a consistent and quality-centered repair. Typically, they may be developed after the first
repair, using the information obtained during the reverse engineering process of the repair.
Figure 2-3 shows an example of the dimensional requirements that would be provided within a
diaphragm partition repair procedure of the type discussed.

2-21

Figure 2-3
Dimensional Requirements That May Be Provided Within a Repair Procedure
Diaphragm repairs done on-site require identification of resources that the utility is expected to
provide versus those the vendor is to supply. This is an important element of diaphragm repairs,
and its delineation should be contained within either the repair procedure or the purchasing
document.

2-22
The following are some of the items of consideration when planning for an on-site repair:
Work location partitions - welding and debris protection
Diaphragm repair stands
Argon and supply
Pressurized air and supply
Fittings for argon and air supply
Welding machines
Power and hookups (connectors/plug ends/pigtail connectors)
Lighting
Lifting and rigging equipment
Layout equipment - tables, rulers, gigs, copper partition backing plates/forms, centerpunches,
and other necessary tools
Consumables
The work scope of a pre-outage bid may be based on either the cost to perform a specific type of
repair or the cost to perform a given quantity of repairs of a specific type. The vendors are to
evaluate their estimated costs accordingly.
The best source of information to develop the scope of repair is the previous outage report and
subsequent recommendations that were noted at the time. The previous outage report should be
detailed enough to provide a way to best guess the upcoming diaphragm repair requirements.
This will assist in defining the total resources required to complete the repairs in a predefined
duration. Typical history of similar pressure, service, and other types of equipment and plant
maintenance history may be reviewed to provide guidance if previous outage recommendations
are not available.
Bidding alternatives and the potential costs savings of competitive offers can be taken advantage
of if the expected scope of repairs is known. The repair procedure can be constructed to obtain a
fixed price for the scope of repairs, or a cost-plus bid can be used after determining the number
of workers likely to be applied to diaphragm repairs.
The following charts are offered to assist in determining either the level of resources that are
likely to be required or the reasonableness of a contractors estimates for repairs. The charts
provide estimates based on two different types of repairs:
Major repair - defined as a comprehensive repair to all of the partitions in a diaphragm half.
This work includes: cutting back the partition approximately 5/8" (15.875 mm) from the
trailing edge or to a partition-section thickness of 1/8" (3.175 mm), rebuilding each partition,
reading and recording area check data for every opening, and repairing sidewalls, horizontal
joints, spill strip grooves, etc., as required.

2-23
Minor repair defined as a repair limited in scope. Minor repairs may include any or all
elements of major repairs but usually do not involve all of the partitions in a diaphragm half.
Dimensions and tolerances for partition shape and opening area may or may not be the same
as for major repairs.
Figure 2-4 provides a way to estimate major repair times based on hours per inch of partition
radial height. As suggested by the chart, the shorter the partition, the greater the impact of
sidewall repair on the repair time per inch.

Figure 2-4
Major Repair Times per Inch of Partition Radial Height

2-24
Figure 2-5 provides an estimate of total major repair time per partition based on the length of the
partition. In this instance, the greater the radial height, the longer the total estimated time to
complete the partition repair.

Figure 2-5
Estimate of Total Major Repair Time per Partition

2-25
Figure 2-6 provides a way to estimate minor repairs. In this case, the shorter the partitions, the
longer the minor repair time per partition. Shorter partitions are generally located in the upstream
portions of the steam path where increased foreign object or solid particle erosion damage is
more likely to occur. Therefore, although shorter, there is typically more work per partition than
is required to repair longer partitions found further downstream.

Figure 2-6
Estimation Tool for Minor Partition Repairs
The times represented in the preceding figures reflect productive repair time. Use the figures to
estimate the repair duration or work scope support requirements, or to evaluate repair
performance. The diaphragm outage scope also includes nonproductive time. Examples of
nonproductive time would include:
Set up time both diaphragm and equipment setup and relocation
Standby time awaiting inspections, decisions, access, or other activities
General support rigging, diaphragm movement, diaphragm readings including dishing,
roundness checks, or other work

2-26
Figure 2-7 inputs were obtained from recording on-site productive and nonproductive time. Six
separate repair events were recorded. Greater repair time detail was obtained in the left three
events. Dividing the total diaphragm repair time into the nonproductive time yielded the data
points as shown in the figure:

Figure 2-7
Total Diaphragm Repair Time Divided by the Nonproductive Time
As shown in the figures, data point scatter does exist and some amount of nonproductive time
will occur. If the diaphragm repairs are not being performed on a fixed price contract, it is
important to note the potential cost savings that might be achieved by appropriate job
management.
The total hours expended to complete diaphragm repairs also include job management and
administrative time. Each scope of repair will dictate the type and strength of overhead support
required. Supervision is a critical element of diaphragm repairs, but sufficient record keeping is
too. The total hours expended to complete diaphragm repairs will be the summation of
productive time + nonproductive time + job management and administrative time.
The diaphragm repair cost is not only a function of hours, but it also may include equipment
rentals, transportation, mobilization/demobilization, consumables, and other items. Consumables
are generally defined as those items that are required to complete the repairs and that are used up
in the process. This should include such items as:
Argon
Filler material

2-27
Sanding disks
Burrs
Files
The nature of diaphragm repairs requires the consumption of tools only to their level of
maximum effectiveness. Using a grinding disc beyond its sharp and useful life causes
overheating of the material and produces a low quality repair. Figure 2-8 represents a
relationship between consumable cost per productive labor hour (left axis) and a percentage of
consumable cost per productive labor hour cost (right axis). The average cost for consumables is
approximately $10/productive labor hour or an average of 18.6% of productive labor dollars. The
relationship between the two methods of evaluation is consistent and useful. Either direct
consumable use can be tracked during a repair and charged appropriately, or consumables can be
charged as a cost per productive labor hour or as a percentage of productive labor costs. The
important element is tracking productive labor.

Figure 2-8
Plot to Track Consumable Costs vs. Productive Labor Costs
Tracking the repair time or cost can be tedious, but a simple database (or spreadsheet) supported
with field time inputs is sufficient to record and provide the information for later analysis and
evaluation. Field inputs can be processed with simple time cards that identify the repair time
expended on a selected diaphragm. If consumables are being tracked, the consumables that were
used during that period should be logged. Outage diaphragm repair cost can range from less than
a quarter of a million to a million dollars. Therefore, effective job preparation and management
applied to this activity can have significant economic benefits and consequences.

2-28
Two measures of an effective repair are the cost to do the repair and the measured restored
turbine section efficiency (gains or losses) from the repair. Accurate details of time spent
(reflected as dollars, or as hours) and job element cost can provide an economic assessment of
the completed repairs. Tracking of turbine section efficiency before and after the outage is a
measure that indicates the performance restored by the repairs. Regained section efficiency and
subsequent energy production costs also assess whether the cost to do the repair was recovered.
For example, Figure 2-9 shows the change in high-pressure (HP) section efficiency after four
separate outage periods. The data was obtained from station instrumentation with a large scatter
in the beginning of the third operating period due to station data calibration problems. Lines have
been drawn through each operation cycle as a visualization aide. The efficiency change is
obvious across the section. Note that all of the efficiency change is attributed to just the
diaphragm repairs. An estimated economic benefit of the section maintenance is the result of
calculating the change in efficiency over time and applying this to a unit-specific operating
value.

Figure 2-9
Change in HP Section Efficiency After Four Separate Outage Periods
Partition repairs of diaphragms are only one element of the total diaphragm repair. Additional
areas of repair include body repairs to the horizontal joint, packing and spill strip hook areas,
and integral spill strips. Repair procedures for various portions of the diaphragm and nozzle are
collected in Volume 2.
2.2.2 Blade/Bucket Replacement or Repairs
Pre-outage planning for blade/bucket activities can be broken down into two major categories:
parts and services. The blade/bucket repair work scope is often labor intensive and may only
require minimal replacement parts and, therefore, a service purchasing action. However, the
repair work scope may also require a significant investment for replacement or repair of
blades/buckets. Under such circumstances, the blade/bucket installation purchase contract may
be negotiated separately from the blade/bucket purchase contract.

2-29
The purchasing documents for services to install or repair in-place blade/buckets should contain
and address each of the requirements previously listed in Section 2.2. Guidelines and examples
of specifications developed exclusively for the procurement and installation of buckets are
contained within Volume 4. Included within a technical specification for the replacements of
blades/buckets and/or shrouds/covers should be checklists that itemize installation requirements,
quality control issues, assembly tolerances, machining tolerances, etc. Often bucket installation
requirements are overlooked, and installation procedures are lean. The skill and knowledge of
the bucket installation craftsman are often relied on as the only assurance of a quality
installation. In many cases, non-OEM bucket craftsmen were OEM trained and used this skill
level to provide a source of qualified expertise for blade/bucket installation and repairs. But, as
these craftsmen age, it is foreseen that utilities will ultimately be required to develop installation
and repair procedures to ensure a quality installation.
The blade/bucket repair and installation procedure may not only include tolerances for
machining of blade/bucket cover, platforms, and other items, but it should also contain additional
items, such as those listed in Table 2-8, along with locations that may require unique attention
within the repair and installation procedure and technical details needed to describe their
manufacture.
Table 2-8
Recommended Information for Bucket Replacement or Repair
Information Sought Special Attention Items Technical Details
Blade/bucket removal First stage Auxiliary buckets/blades
Blade/bucket lean (off radial
condition)
Coated vane sections Dimensional data
Attachments between
blade/bucket at root/platform,
at covers
Tuned L-0, L-1 and often L-2
rows
Moment weights for tuned
buckets/blades
Blade/bucket fit to rotor
assembly clearances, wheel
rolling
Tangential, axial, radial entry
roots. Finger dovetail, straddle
dovetail roots. T root type
Root form, inspection
requirements, tolerances and
surface finish
Tie-wire installation assembly
locations, brazing
Hardware tie wire, covers,
pins
Row assembly and closure for
tangential entry buckets
fitting/drive up/pinning and
staking.
Closure procedure for
bucket/blade
Cover tenon peening

Blade/bucket repair and installation procedures may be either broken down into separate
procedures or grouped by steam path location and attachment style, and in some cases, according
to blade/bucket material.

2-30
Part requirements may be broken into two activities, purchasing new or refurbished parts, or
repairing existing parts. Outage duration, economic posture, and other factors may dictate the
direction of repair during an outage or replacement with purchased buckets. The parts
specification has two fundamental elements; the first describes the geometry of the blade/bucket
and the second describes the material. Nearly everything else falls under these two categories.
The material section defines what the blade/bucket and hardware are to be manufactured from
and should include the following items:
Chemical composition
Heat treatment
Mechanical properties
Testing requirements
Each section should contain appropriate standard references for processing and materials as
appropriate. A final report containing all the material information, dimensional results,
inspection results, and other information should be supplied with the blades/buckets. A minimum
amount of information is required to begin the replacement process if detailed blade/bucket
information is not available before an outage and if the outage work scope includes manufacture
and replacement of the blade/bucket during the outage. The following information will assist in
the bidding and planning process:
Number of blades/buckets
Type of blade/bucket attachment
Overall blade/bucket dimensions
Vane form/type
Cover type and grouping
Tie wire type/size/arrangement
Information may be obtained from past outage reports, rotor work, and other sources.
Photographs of the row to be replaced taken during outages may also provide sufficient
information for bidding and planning.
Blade/bucket repairs require the same type of information as manufacturing replacements but not
to the same level of detail. Whether the blade/bucket will be repaired in place or removed from
the rotor and then repaired also dictates the amount of information and planning required.
As a final note, the degree of technical information used to qualify a replacement bucket is
dependent on the history of the design in service. If a new or modified design is being purchased
to replace a design that has experienced a problem, it is advisable to seek information that can be
used to establish the soundness of the new design. Volumes 6 and 7 provide explicit information
for many of the most commonly replaced blades, that is, those that are most likely to experience
damage during a period of extended service. This information in Volumes 6 and 7 on stresses
and operating frequencies provides a way to contrast and calibrate an improved design.

2-31
To take advantage of this database, the plant should include a requirement within the
procurement specification that makes purchase contingent upon the completion of an
independent examination of the new design. In support of this requirement, provisions should be
made within the purchase document to obtain either a sample of the design (for reverse
engineering) or the cooperation of the supplier to supply details under an agreement of
confidentiality. Examples of such requirements are included in Volume 4.
2.2.3 Bearing and Shaft Seal Repairs
During service, physical damage to rotors may be caused through rotating elements coming in
contact with stationary objects. This typically occurs in bearing or sealing areas, and is caused by
contaminants either embedded in or building up on the stationary component. Physical exterior
rotor damage can also be caused by thermal-induced eccentricity or rotor imbalance. This causes
the rotor to contact stationary sealing areas typically near areas of the rotor maximum
displacement and reduced clearance.
These conditions may occur during startup or operation as a consequence of load changes. As an
example, material buildup on an oil deflector can occur in service and slowly machine the
rotor as more buildup occurs. Particles may accumulate within the bearing babbitt and slowly
score the rotor bearing journal surface, especially when on turning gear or transitioning from
turning gear operation to hydrodynamic operation. Some damage to these surfaces is tolerable
and can be remedied during an outage by strap lapping the damaged surface. Other exterior
related damage can occur from chemical attack and may be seen as pitting or cracking,
depending on the rotor and its location, and may result in stress corrosion cracking (SCC).
Outage reports, previous damage identification, and recommendations become useful tools in
planning for remedial action for the rotors during the outage. Three methods of repair are
generally available: machining the rotor in place, machining the rotor on-site, or machining the
rotor off-site. Rotor size, proximity to repair facilities, cost, total rotor repair scope, repair
requirements, and outage duration will all factor into the method of repair selected.
The rotor geometry necessary to construct a repair procedure is listed in Table 2-9.
Table 2-9
Geometry and Tolerances Required to Support a Repair Procedure
Journal Rotor Other
Journal sizes Rotor length Diameter to be machined if not journal
Journal length Rotor weight Machining length
Journal location on rotor Maximum steam path diameter
Coupling diameter and geometry
Proximity to obstruction
Note: In-place machining will not require all listed items.
Diameter Taper TOLERANCES
Out of Round Surface Finish

2-32
The rotor geometry will dictate support and setup requirements for the rotor-turning device
(RTD or lathe) for both on-site and off-site repairs. Journal sizes (or appropriate rotor support
location during machining) will be used in determining RTD bearings or vee-pads and shimming
requirements for rotor leveling. Coupling information is required for drive plate setup. Overall
rotor length and maximum diameter are used to determine RTD bed length and swing. Rotor
weight may be required to determine the loading at the support points on the rotor. Figure 2-10
shows examples of information on rotor weight and coupling geometry that is generally required.

Figure 2-10
Examples of Rotor Weight and Coupling Geometry Measurements

2-33
Required machining dimensions may be included within the repair procedure, especially for seal
areas. However, in rotor journal repairs, the journal finish dimension is often determined by the
minimum cleanup to restore the journal to serviceable condition. Bearings are then made to fit
the rotor journal. The repair procedure should include the tolerances shown in Table 2-9.
For off-site repairs, the repair procedure should include rotor handling and protection
requirements. For on-site repairs, the repair procedure should either identify the services
availableelectrical, air, and wateror require the repair vendor to identify the service
requirements for both the RTD and machining equipment.
2.2.4 Generator Repairs
Pre-outage procurement planning for the generator (a rotating excitation system may also share
some of the same planning and repair activities) begins with defining the type of the generator
and its components. Generators are coded and subsequently classified by their manufacturers.
Coding typically identifies how they are cooled and the type of construction, both for the stator
and rotor. As an example, generator rotor cooling may be by either air or hydrogen. Stators may
be gas-cooled or liquid-cooled. Each form of cooling will have distinctive related components
and maintenance requirements. Types of construction coding also apply to both the rotor and
stator; characteristically, the number of poles is described in the generator coding. Components
of a generator can be broken into three major areas identified in Table 2-10.
Table 2-10
Classification of Generator Components
Stator Rotor (Field) Auxiliaries
Bearings Body Electrical conduction system
Core and windings Collector Excitation system
Electrical and hydraulic connections Conductor (Coils) Rotor cooling system
Fans Connections Sealing
Frame and end bells Retaining rings Stator cooling system
Seals Wedges

Retaining rings may be mounted in a variety of ways but are mounted either to the body of the
rotor or to the spindle portion of the rotor. Figure 2-11 shows a silver-plated ring/shell that
bridges the joint between the retaining ring and rotor body. It has fingers that extend into the coil
slots that contact the slot wedges and the retaining ring, providing a current-carrying capability
to protect the field under fault conditions.

2-34

Figure 2-11
Examples of Shells Used to Bridge Between the Retaining Ring and Rotor
Each of these areas may have distinct and unique requirements to support the disassembly,
inspection, repair, reassembly, and testing activities during an outage. The types of tests typically
performed on a generator and when they are required are summarized in Table 2-11.
Table 2-11
Generator Tests and When They May Be Performed
Types of Tests When Testing Is Performed
Winding resistance Prior to the outage while the unit is on line, for example, hydrogen
leak test
Insulation resistance During assembly, for example, NDE
Dielectric strength During reassembly
Shorted turns After reassembly when the unit is off line, for example, insulation or
air leak test
Hydraulic integrity After reassembly when the unit is off line, for example, hydrogen
leak test
Sealing capability
Mechanical capability

Testing is an integral part of the generator outage. Therefore, coordination to be obtained from
the plant must be identified in the procurement plan and integrated into the plant schedule.
Knowing the parts breakdown for the components that are to be disassembled and reassembled
provides a way to identify replacement components. These components can be integrated into the
pre-outage purchases that are to be made. For example, if retaining rings are to be removed, parts
to have available should include insulation, locking keys, snap rings, and amortisseur (damper)
windings. In some cases, replacement parts may be needed or vendors coordinated to refurbish
parts removed during the outage.

2-35
Numerous specifications, which can be found in Chapter 8 of Volume 2 of the guidelines, have
been developed to guide the repair to major generator-exciter components and systems.
Examples of these specifications include:
Rewedge of a water-cooled stator and a hydrogen inner-cooled stator
Repair to babbitted and nonbabbitted hydrogen seals
Inspection of a brushless and Alterrex exciter
Inspection of a hydrogen and nonhydrogen seal oil system
Rewind of a water-cooled stator and hydrogen inner-cooled stator
Procedures for torquing stator bolts in a generator
Other procedures are being developed and will be added to Volume 2 as they are completed.
During service, operational abnormalities may provide indications of additional maintenance
requirements to be planned. Operational damages may sometimes be anticipated, knowing the
event and potential subsequent damage mechanism. Checking operating logs and outage reports
are ways to provide insight into the health of the generator.
The following are some abnormal operating conditions that may result in additional maintenance
during an outage.
Generator internal clearances are not usually close enough to see damage from excessive
vibration (mechanical or thermal imbalance) during operation (except in the bearing and any
sealing areas). Typically, the shaft sealing areas will have the smallest clearance and are,
therefore, most susceptible to damage from excessive vibration.
Generators are typically designed for some voltage variation. A manufacture may specify a
5% over- or under-voltage design rating. Abnormal voltage operation maintenance concerns
focus on damage created during these periods because of increased flux densities and core
heating. Under-voltage operation requires increased excitation and may result in additional
wear/damage to the excitation system.
If a generator is supplied with excitation and system power but the turbine loses the driving
force from the steam, the generator can effectively operate as a synchronous motor and drive
the turbine at rated speed. This operation is known as motoring and is not necessarily
harmful to the generator, but it may be damaging to the turbine. No cooling of turbine
buckets will occur with the steam flow blocked. The buckets, especially at the larger tip
diameter locations, will spin at rated speed in a stagnant atmosphere and may heat quite
rapidly.
Loss of field excitation can produce severe heating in the rotor. Without excitation, the unit
becomes an induction generator where significant surface current is induced in the rotor body
and wedges. A result may be arced or burnt wedges.
Out-of-frequency operation may also have more detrimental effects on the turbine than on
the generator. The buckets of various stages in the turbine may be tuned to operate within a
reasonably narrow operating speed (frequency from a generator perspective). Off-speed

2-36
operation of those stages may induce harmful stimuli to the buckets, resulting in failures or
damage uncovered during a maintenance outage. One issue for the generator is reduced rotor
cooling as a result of off-speed operation, and subsequent problems with regard to heating
may also occur.
Transients and faults may result in high rotor currents and resulting temperature increases,
but physical or mechanical damage may result from sudden changes during operation. The
mechanical shock induced by strong changes in the magnetic field may distort end turns,
loosen or break ties, shift end turn blocking, or possibly damage insulation.
Unbalanced current operation in a generator designed to operate with balanced three-phase
current loading can cause overheating of one phase of the stator. Unbalanced currents in the
stator also produce a nonsymmetrical magnetic field. The field sees the changes in flux as
traveling in the reverse direction (negative sequence). Damage to the field is dependent on
the magnitude of the negative sequence currents imposed on the field. Additional heating
occurs in the rotor surface and may cause damage to the wedges and retaining rings. These
conditions may occur during a ground fault incident.
Performing repairs on generator components may require asbestos removal or interaction with
other materials that are identified as hazardous waste. Therefore, included in the pre-outage
planning is the identification of all products and wastes to be interacted with during the repairs.
This includes obtaining all the appropriate product identifications (Material Safety Data Sheets
or MSDS); material handling and waste disposal procedures; and notifications to the appropriate
persons, departments, or agencies.
2.2.5 Valve Part Replacement and Repair
Valve component manufacture or repairs to spares are often done during non-outage periods;
therefore, the scope of repair is easy to determine. Preparation for outage repairs requires a
review of past outage recommendations or historical activities to develop the anticipated repair
scopes and planning. The actual repair or manufacture of replacement parts requires the same
elements, whether performed during an outage or at another time.
Damage mechanisms to valve components are usually from:
Wear on sliding surfaces
Solid particle erosion
Water/steam erosion
Bending (stems)
Cracking
Repairs required from these damage mechanisms are normally done to the following valve
components:
Stems
Discs

2-37
Bypass valves
Caps
Actuator guides
Seats
Determination of the scope of repair is done by evaluating the serviceability of the component.
This begins with cleaning the part so both nondestructive testing (NDT) and a dimensional
analysis can be performed. The repair procedure may contain the requirements for the
serviceability evaluation, or the evaluation may be done separately and the repair work scope
provided from it. In either case, the information should be documented to become part of the
repair work package.
In order to track the repair item to its repair work package information, it may be necessary to
mark or uniquely identity the item being repaired. Caution is always advised in the type and
location of markings. If performed inappropriately, the marking may be removed during the
repair process or may even become a point of failure during future service.
Repair estimates may be obtained with a known repair scope. The value of a repair is determined
by the utility and may be expressed as a fixed dollar amount or a percentage of a replacement
part. This value should be determined in advance of the repair. Replacement part manufacture
may be required if the repair exceeds a value of a new part.
Repairs are completed in accordance with the repair procedure that contains the appropriate
material and dimensional data. At this point, the repair process may not differ from original part
manufacture. Both require material identification, including material processing requirements
such as nitriding, and dimensional information that includes tolerances. Replacement part
information may be contained within the repair procedure or provided separately as needed.
EPRI report Guidelines and Procedures for Steam Valve Condition Assessment (1008352)
provides a series of disassembly, condition evaluation, and reassembly procedures for 12 major
types of fossil and nuclear valves. Additionally, EPRI report Turbine Steam Valve Diagnostic
Testing (1004960) provides details on testing procedures that can be used to determine the
current condition of a turbine steam valve during operation. These tests help determine the
degradation of the valve stem, bushings, seats, and springs as well as describe how steam seal
leakoff testing can be performed to further diagnose valve condition.
2.2.6 Parts Stores Review
Before an outage, it is essential to review the parts requirements for both stock (warehoused) and
non-stock (direct purchase, just-in-time, stock supplements) parts to support routine work and
planned work. Routine work is defined as work associated with the normal disassembly,
inspection, and reassembly of the turbine-generator. Parts to support routine work are itemized in
Table 2-12.

2-38
Table 2-12
Parts and Consumables Used to Support Routine Work
Parts Consumables
Gaskets Rags Sealants Fish paper
O-rings Oil adsorption
materials
Adhesives Shop ticket holders
Bolts Triple-boiled linseed oil Markers Plywood
Washers Pails and buckets Liquid nitrogen Pallets
Nuts Welding cloth Dry ice
Bushings Safety wire Fuse wire
Bearings Shim stock Tongue depressors
Valve components Paraffin wax Oak cribbing

Planned work is work that is not part of the normal disassembly and reassembly process. Planned
work can be as simple as designating the replacement of packing as required or as complex as a
complete rotor change-out. Reviewing historic usage is one step in evaluating the status of a
plants stock level to match outage requirements. A review of non-stock parts used during the
last outage coupled with its work scope is also beneficial. It is important to evaluate the status of
critical items at a timely interval because warehouse stock levels are reduced to meet utility
economic guidelines, and part ordering is often dictated by just-in-time delivery cycles. Missing
a simple gasket can cause delays at the wrong time during unit assembly.
Desktop or LAN-based databases introduced in Section 2.1.1 are an appropriate tool to assist in
reviewing parts. Resident databases allow the reviewer access to information that may be queried
to meet a specific review question. The master parts database should contain all identified parts
associated with the turbine-generator. This includes both stocked and non-stocked items. The
master parts database should contain as much history of part use as possible.
The location of use is the second database necessary for parts review. The part use location
database can be constructed with information available from unit construction or acquired
through time. The information can be organized in a variety of formats. One format used by an
OEM provides the location information identified by both numeric and location descriptive
coding. Regardless of the method used, the coding or grouping location information becomes the
basis for querying the database to determine part requirements. Figure 2-12 shows one method of
coding or grouping part location information.

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Figure 2-12
Part Location Information
It is useful to build the part location database (catalog of use) with grouping level descriptions
that will aid in planning as well as in finding associated parts. One method is to group and divide
parts into four levels, three of which identify the location of use and the fourth identifies the part.
In most cases, this will provide a sufficient breakdown to find a part by beginning at the highest
level and drilling to the part itself. The drilling process excludes all parts not associated with
the higher-level item. It also helps in identifying all like parts used within a specific section.
Figure 2-13 visually depicts this breakdown.

Figure 2-13
Four-Level Part Location Hierarchy
"Section is the highest level of identification within either the turbine or generator. The
subsection is the next logical breakdown when observing the makeup of the section.
Location is the third descriptor and might not always be needed. The last item is the
common name associated with the part. The common name may be a single nickname or

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multiple nicknames normally used for that part by the utility. A nickname is always included.
For example, one commonly used part is one that the OEM identifies as the outer stationary
sealing component for the rotating row of buckets. This item is called a steam deflector;
however, this item is often called simply a spill strip. So, spill strip is used as the familiar part
identifier or nickname.
The OEM often provides some form of part use information. This information can then become
the seed or foundation for the parts catalog database. The information provided by the OEM
might not provide sufficient breakdown or organizing details, so grouping levels are added to the
part use location information. The combination of this information now provides a familiar and
useful tool. The following are two examples of the grouping structure.
The database contains all the relationship information for each part location. Within the database,
these are the fields for each record. The record is all of the information that describes a part.
Coded in the database is the ability to display only the appropriate information, limited by the
items selected to be queried.
As in Figure 2-13:
1. If HP is selected as the section:
N-1, N-2, and shell (or all subsections associated with HP) would be displayed as
subsection choices for further drilling.
No other subsection is displayed.
2. If N-1 is selected as the subsection:
Grv-1 and Grv-2 (or all locations associated with N-1) would be displayed as location.
3. If Grv-1N-1 is selected as the location:
Only those parts associated with that location would be displayed.
This approach moves down to a specific item. To look at all parts of specific types associated
within a level, make a selection at the highest level desired and choose from the available parts.
For example, if HP is selected as the section and Key is chosen as the part, four keys will appear
in the resulting listing.
If followed carefully, this system can become an extremely valuable tool. For instance, to list all
the gaskets associated with main steam control valves (MSCVs), select MSCV as the section,
and choose gasket as the nickname. All gaskets used within all MSCVs will be displayed, and
the quantities required at each location will be listed. By producing a report based on this query,
a bill of materials (BOM) of replacement parts is created and becomes the shopping list of
items required. Comparing this list to the parts available shows part requirement needs.

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2.2.7 Miscellaneous Turbine-Generator Exciter Parts, Bolts, Nuts, and Other
Parts
The need for miscellaneous turbine and generator parts should be identified from the previous
outage report, outage recommendations, design changes, or modifications to existing parts.
These parts may be items that can be reverse engineered during an outage or manufactured
during non-outage periods. The requirements to produce parts are the same for both scenarios.
Material identification of the part or assembly is required. Most materials used for turbine or
generator components can be identified with an equivalent ASTM (American Society for Testing
and Materials) number. A material ASTM number is a precise statement of a set of requirements
to be satisfied by a material, product, system, or service that also indicates the procedures for
determining whether each of the requirements is satisfied. Other material choices may come
from such standards such as AISI (American Iron and Steel Institute).
A drawing or sketch is used to define part geometry. Information obtained through reverse
engineering may be in an electronic format that is easily converted to a fabrication drawing or
sketch. Numerically controlled machine tools may be able to directly use the electronic drawing
or sketch information. Manufacturing drawings must contain functional tolerances on the
machined surfaces. Tolerances may be defined by the function of the part or through experience.
2.3 Identifying and Procuring Specialized Support
The turbine-generator engineer may be faced with a challenging problem when it is necessary to
identify and locate the appropriate resources to resolve an issue or supply a part. It may be
necessary to expand your database of available resources to perform the routine activities of
turbine-generator repairs.
Often, the first hurdle to overcome in problem solving is the identification of available resources.
Traditional tools include:
Yellow pages and directory listings
Trade publications
Annual trade publication handbooks
Professional and trade organization listings
Institute of Electrical and Electronics Engineers, Inc. (IEEE)
As regional and world boundaries change, the traditional methods of resource identification may
no longer suffice. The Internet adds another resource identification method to the traditional
toolkit. The Internet can be a maze of confusion or an ocean of information that can be tapped
with the right resource tools and assist the turbine engineer trying to find available resources.

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Suppliers and vendors who supported the last outage may no longer be in business by the next
outage. One of the challenges facing the turbine engineer is being able to identify and obtain the
right service or part in the right amount of time at the right cost. Examples of items that can
assist in this process are summarized in Table 2-13.
Table 2-13
Examples of Specialized Sources for Locating Vendors and Supplies
Trade Crafts Trade Magazines Seminars/Meetings Sponsored by
NDE Electric Light and Power American Society of Mechanical Engineers
Sandblasting Power Magazine International Joint Power Generation Conference
Shot peening Power Engineering Electric Power Research Institute
Welding Turbomachinery American Welding Society

2.3.1 Lead Times to Arrange for Different Types of Support.
Service support lead times may differ from parts-related lead times. Whenever possible, it is
advantageous to secure services as far in advance of outages as possible. Outage season brings
competition for resources between utilities because windows of opportunity may be limited
during outage season for preferred resources. As a rule, purchase orders should be issued at
least three months prior to the beginning of an outage.
It is often preferable to obtain all parts prior to an outage, but economic factors may dictate
leaving certain items to be purchased within the outage window. Purchases made then are based
on inspection results, not on recommendations or pre-outage assumptions. The limiting factors
for parts purchases during outages are that inspections must be completed early in the outage so
that part orders can be made. Additional limitations are the availability of materials and lead
times required by the manufacturer. Table 2-14 provides considerations and typical estimates for
selected activities and lead times.

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Table 2-14
Selected Activities and Estimated Lead Times
Type Item Lead Time Considerations
Service Diaphragm
repairs
Four months Many of the diaphragm repair vendors use
independent repair craftsmen. These resources
may often be shared by multiple vendors.
Service Bucket
repairs
Three months Similar to diaphragm repair craftsmen. However,
the number of craftsmen required per outage is
usually less; therefore, this lead time may be
shortened.
Service Technical
direction
Three months
Service Balancing Three months
Service Sandblasting Three months
Service NDE Three months
Service Generator
repair
Three months
Service Coating or
plating
During outage
Service Glass
beading
Three months
Parts Buckets Three to six
months
Possible to manufacture during outage if there is a
long outage duration. It is best to have spares on
hand prior to the outage start date.
Parts Packing and
hardware
During outage Multiple vendors are available with lead times
such that these parts may be identified and
purchased during the outage. Identification is
required early in the outage.
Parts Spill strips
and hardware
During outage Multiple vendors are available with lead times
such that these parts may be identified and
purchased during the outage. Identification is
required early in the outage.
Parts Fasteners During outage Limitation may be materials for higher
temperature bolting. Typically, these items may be
either purchased as part of the pre-outage
process or purchased during the outage. For the
latter, identification is required early in the outage
to allow for lead time.
Parts Field copper Six to 12
months

Parts Retaining
rings
12 months +

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2.3.2 Web Searches: Key Words or Identifiers to Produce Supplier Lists
The ability to see information on the Internet is through web browsers like Netscape and
Internet Explorer. The ability to find and then extract information from the Internet through the
web is accomplished by using one of the following two primary methods:
Directories. Directories contain human inputs for their listings. A short description is
submitted to the directory for a web site and assigned to the appropriate category and
subcategory. The search looks only for matches in the description. Because of the human
organization, the directories can often provide better results than search engines
Search engines. Search engines create listings automatically. Search engines examine or
crawl through the web, and then humans examine the results of the search. Search engines
use tools to explore and catalog a web site and its information.
All search engines contain the same basic web-exploring tools and methods, but the difference is
how each engine is tuned. That is why the same search item used by different search engines
may produce different results. The difference is also the power of the search engine. There are at
least a dozen major search engines as well as a myriad of specialized search engines, with more
being introduced as the web grows in both size and complexity.
In order to use the web and search engines as effective resource information tools, it is essential
to understand how a particular search engine is cataloged or indexed and how to construct
definitive searches. Most search engines will not only accept direct single word requests (for
example, plant, turbine, etc.) but will also understand constructed searches (such as power plant,
steam turbine, etc.) by employing a Boolean technique.
It is important not only to identify key words for searches associated with turbine-generator
repairs or parts purchase or replacement but also to know the relative strengths and weaknesses
of a search engine and its querying techniques to be able to obtain meaningful results. When
accessing information on the Internet, the following items are helpful:
Become familiar with the type of web search devices available.
Become familiar with Boolean operators for searches.
Turbine-generator general keywords are helpful.
Maintain your own database of resources and URLs indexed to your needs and component
identifications.
2.4 Scaffolding Requirements
Scaffolding provides access to various areas of the turbine-generator that are either inaccessible
or unsafe to work on without temporary support structures. The scaffolding must be in place at
the right time with access to the right area in order to support the turbine-generator outage.
Scaffolding must also be constructed in a safe manner allowing a safe entrance and exit from the
area. The scaffolding must not only provide access, but it must also act as a secure work platform
as appropriate. Items that a scaffolding plan should include are listed in Table 2-15.

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Table 2-15
Basic Elements of a Scaffolding Plan
Item Comment/Example
1 Description of activity Install steam lead scaffold so machinist can dress face of steam
flange. Need access to both flanges and to be able to maintain
HP shell work below scaffolding.
2 When the scaffolding is
required

3 How the scaffolding is to
be built
From where, to where, with access to what. Identification of
support requirements personnel, materials, equipment.
4 Additional craft support, if
required
Insulators to remove insulation which will provide footing for
scaffolding leg.
5 Modifications required Unique access to special areas during assembly and
disassembly. Up and down to facilitate turbine-generator repairs.
6 Scaffolding component
requirements
Quantities, type, and staging area.
7 Safety concerns All valves and equipment in the area will be hot. Be careful and
dont get burned.
8 Regulatory compliance
9 OSHA Standards: Part
1926
Safety and Health Regulations for Construction - Subpart L
Scaffolds.
1926.450 Scope, application, and definitions applicable to this subpart.
1926.451 General requirements.
1926.452 Additional requirements applicable to specific types of scaffolds.
1926.453 Aerial lifts.
1926.454 Training requirements: Appendix A-E Subpart L Scaffolds.

The items of a scaffolding plan that should be verified prior to an outage are as follows:
Is there a scaffolding erection plan that identifies all of the components that correspond to the
application?
Footing or bearing requirements for the scaffolding.
Scaffold duty ratings should be assigned for locations based on expectations of use (for
example, personnel only, equipment and personnel, etc.).
Planking span dimensions corresponding to loading requirements: light duty 25 pounds
per square foot (11.3 kg/m
2
), medium duty 50 pounds per square foot (22.7 kg/m
2
),
heavy duty 75 pounds per square foot (34.0 kg/m
2
).
Safety factor scaffolding system should be able to support x times the load required
(for example, a safety factor of 4 means the components used within the design can carry
four times the rated load before possible failure).

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Toe board height and clearance requirements
Overlap of planking (if wooden planking is used).
Planking material, size, and grade requirements.
Fastener material, size, and grade requirements.
Locking wire material, size, and grade requirements.
Handrail/guardrail height and span requirements.
How is the material to be staged?
Are there pre-staging sites?
Is there a central delivery location and supporting distribution system?
Are component storage locations clearly identified (bins, racks, etc.)?
Has the required amount of material been identified and staged?
Have all the scaffolding locations been identified?
Is there a process for safety inspection after erection of the scaffolding? Prior to use, the
appropriate supervisor responsible for scaffolding completion should visually inspect the job
site and ensure at least the following:
Integrity of the hardware
Proper access (ladders, etc.)
Guardrails
Toe boards
Scaffolding locks in place
Appropriate decking and structure to meet identified requirements
Completion and attachment of scaffolding inspection/release form (ready to use) to
scaffolding at access location
Does the scaffolding construction plan match how the scaffolding is to be used?
Has the scaffolding erection schedule been completed and cross-referenced to the outage
plan?
2.4.1 Customization of a Scaffolding Plan
Typically, the items of a scaffolding plan that will require modification during an outage are the
following:
The timing of the scaffolding erection may be impacted by disassembly or reassembly.
The planned scaffolding foundation location may change as a result of a change in machine
disassembly or reassembly, for example, planning to build off the turbine-generator lagging
when the lagging has been previously removed.

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Loading requirements may change, for example, if the plan was only to inspect and repairs
are required, the scaffolding may be required to support equipment.
Planned access to scaffolding may change during the outage that could require a modification
to the scaffolding plan.
2.4.2 Ways to Reduce Scaffolding Erection Time
Constructing easy-on/easy-off platforms and accesses often significantly reduces disassembly,
repair, or reassembly time. Such items would include:
Access to cross over pipe flange bolting instead of scaffolding
Stands for valve components that include platforms instead of scaffolding
Covers/platforms instead of planking for access openings
Shell openings
Areas in turbine pedestal
Complete fabricated assemblies installed by crane, which include:
Supporting structure
Grating
Unique tool holding or storage areas
Aligning, orienting, or locking devices
2.5 Safety Procedures
Safety is always considered a top priority during a turbine-generator outage. The components
worked with during a turbine-generator outage may be heavy, awkward to handle, difficult to
access, and require special handling and protection. Safe working attitudes, actions, and
conditions must be maintained at all times. Safety attitudes should be reinforced daily during job
planning meetings and tail boards and at other opportunities. Safe actions, near misses, and
unsafe actions should be noted, commented on, and corrected as appropriate.
Good work environment conditions should be maintained at all times during an outage. Good
housekeeping is a visual indication of safety attitudes. Clean and orderly work areas reflect good
safety attitudes and make the work easier. Trash should be cleaned up and disposed of; lumber
and cribbing areas should be neatly organized with any nails either removed or bent over so they
are not exposed. Tools and equipment should be picked up and put away. Hoses, extension
cords, and general clutter should be kept out of the walkways. Portable overhead cable/hose
racks should be used to maintain clear walkways. If none are available, cords, cables, and hoses
should be taped down to reduce tripping hazards. Liquid spills and oily surfaces should be
cleaned up immediately to reduce slipping hazards. This includes the bearing standard areas.

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The following are other indicators that reflect a safe working attitude:
Are proper rigging practices being followed?
Use of eye bolt
Cable angles
Use of shortcuts
How are openings handled?
Many are exposed during an outage - shells, standards, valves, etc.
Properly barricade openings using marking tape, temporary handrails, etc.
Cover the opening as soon as possible.
Minimize personnel traffic in the area until the opening is covered.
Is eye protection worn?
Is equipment tagged out and released for operation properly?
How is equipment reactivated for in test operation?
Is there finger- and hand-safety consciousness?
Gloves are worn as appropriate.
Hand- and finger-safety awareness is practiced when using sledgehammers, lifting, etc.
2.5.1 Plan for Insulation/Asbestos Identification, Handling, and Disposal
Most, if not all turbine-generator manufacturers stopped using asbestos or asbestos-impregnated
products in the late 1980s. However, many, if not all, of the turbine-generators built before then
contained some form of asbestos. Most often, asbestos was used in some form of insulation (both
thermal and electrical), but it can also be found in sound-deadening materials, sealing materials,
and higher temperature gasket materials. Table 2-16 lists typical areas where asbestos can be
found around the turbine/ generator.

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Table 2-16
Typical Locations Where Asbestos Is Found Around a Turbine
Turbine and Components
Material Type Location
Heat retention material Casing/shells High-temperature steam piping
Steam packing exhauster Main steam valves
Non-return valves Auxiliary steam valves
Refractory mud Cloth used for insulation and blankets

Sound insulation Turbine enclosures Lagging
Gaskets (spiral and
flat)
Shell and casing: Access, inspection hole, balance hole covers
Main steam piping: Piping flanges and crossover flanges
Valve assemblies: Heads, control valve stands, bolted in seats
Valve assemblies: Leak-off flanges and attachment flanges
Secondary/auxiliary piping Heat exchanger
Packing Steam packing, valve stems, and cylinder rod seals
Shaft seals: Lube oil system, valve motors, non-return valves
Valve seals: Butterfly valves
Generator
Material Type Location
Sound insulation Generator lagging
Gaskets (flat) Heat exchangers: Tube sheets, cooler heads
Generator access covers Motors
Thermocouples Generator heaters
Generator: Tape, blocking, and insulation
Electrical wiring Exciter

Asbestos abatement is a comprehensive program that controls fiber release from asbestos-
containing materials and includes identification, removal, encapsulation, enclosure, repair,
demolition, and disposal. Each element requires planning to accomplish abatement in a safe and
timely manner. Elements of an abatement program are itemized in Table 2-17.

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Table 2-17
Items Recommended in an Asbestos Abatement Program
Program Elements Actions or Issues
Awareness and
understanding of asbestos
rules and regulations
OSHA 29 CFR 1910.1001 - Work Place Exposure Standards for
Asbestos
OSHA 29 CFR 1926.58 - Asbestos Standard for Construction
Work
EPA 40 CFR Part 61 National Emission Standards Hazardous
Air Pollutants Subpart M, National Emission Standard for
Asbestos
Asbestos identification and
sampling procedures

Work procedures Large demolition, renovation, and removal
Small demolition, renovation, or maintenance
Glove bag removal
Air monitoring
Work notification
Medical surveillance
Record keeping
Asbestos disposal
Training
Additional details Warning signs
Warning labels
Enclosure details
Disposal container requirements

2.6 Environmental Planning
During an outage, a greater variety and larger quantity of chemicals are used than during non-
outage periods. The chemicals may be used for cleaning, bonding, sealing, and other purposes.
Consequently, environmental issues and concerns should be a part of every outage planning
process. Requesting the Material Safety Data Sheet (MSDS) for each chemical brought onto the
site is a necessity. Providing access to information about all chemicals used by a utility is a
requirement. Having the MSDSs available complies with Right to Know requirements and
makes good sense.
MSDS information about all chemicals is required before the chemicals are actually brought on-
site. The MSDS form should be submitted in advance of the outage to appropriate safety
personnel at the site to allow their complete review without impacting the scheduled activities.

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Contractor or service personnel should be responsible for reporting and cleaning up any spills
caused by their personnel. The clean up should be accomplished in accordance with the latest
federal and state rules and regulations. Any spill should be reported to the utility.
Unless otherwise specified, the contractor or service personnel should be responsible for the
removal and disposal of any chemical or by-product that is considered hazardous by regulation.
Disposal should be made to a licensed and certified facility approved by the utility.
2.6.1 EHC Fluid
Fluid handling should be done in accordance with the MSDS instructions and precautions, with
the handler wearing the appropriate personal protection equipment (PPE). Spills of any fluid
should be attended to immediately. Spills may not only pose an environmental but also a safety
risk.
A synthetic phosphate ester fluid is typically used for electrohydraulic control (EHC) systems.
Phosphate ester fluids are used in turbine controls because of their higher flash point and fire
point over their petroleum-based counterparts. A phosphate fluid, with the look and feel of a
light mineral oil, should not be confused with petroleum-based hydraulic fluids. The phosphate
fluid requires specific safeguards and procedures to maintain its usability as a serviceable
hydraulic fluid.
EHC fluid is shipped in lined 55-gallon (208 L) drums to protect the fluid from contamination.
Fluid removed from the EHC tank reservoir should be placed in suitable containers to prevent
fluid contamination. Drum tops should be cleaned with a non-chlorinated fluid to prevent
contamination before transferring the EHC fluid to and from the tank. Under normal operating
temperatures, phosphate ester fluids do not emit any harmful vapors; the MSDS should be
consulted for additional information regarding PPE. Appropriate measures should be taken when
the fluid contacts the skin. Phosphate ester fluid has minimal skin exposure risks, but the areas
should be cleaned in accordance with the MSDS and exposure limited. Oral ingestion does pose
a health risk; therefore, immediate medical assistance should be obtained in accordance with the
MSDS.
Phosphate ester EHC fluid affects the serviceability of items used in and around EHC systems.
Most items commonly used with petroleum-based hydraulic fluids are not compatible with
phosphate ester fluids. For that reason, caution should be taken when allowing the fluid to be
exposed to the following items:
Seal materials
Improper seal materials can swell, soften, or become eroded and cause leaks or binding of
moving parts.
Preferred material Fluorocarbon (FPM) - Viton.
Acceptable substitutes [2]
Ethylene-propylene (EPDM) suitable under certain conditions

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Butyl rubber
Teflon for pressurized water reactors (PWRs). Teflon is not used in boiling water
reactors (BWRs) because of degradation from radiation.
Packings
Improper packing materials can swell, soften, or become eroded causing leaks or binding
of moving parts.
Preferred materials - Teflon, fiber sheet.
Acceptable substitute - RTV silicone.
Paints
Standard coatings will soften and peel with the possible result of a system malfunction.
Preferred material - special phosphate ester resistant, amine-cured epoxy.
Acceptable substitute none.
Electrical wiring insulation
Some insulation coatings will soften and eventually decompose after exposure to
phosphate ester fluids.
Preferred materials - silicon rubber, Teflon, nylon, polyethylene, or polypropylene.
An EPRI guide is available that not only discusses the environmental issues but also provides
plant personnel with information about EHC systems. Electrohydraulic Control (EHC) Fluid
Maintenance Guide, 1004554, [3] can help plant workers improve the system reliability,
performance, and plant maintenance practices. Many topics are covered in this guide including
fire resistant fluids, fluid purification, fluid sampling and analysis, condition monitoring,
material compatibility, and operating limits.
Another EPRI guide, General Electric Electrohydraulic Controls (EHC) Electronics
Maintenance Guide, TR-108146, [4] provides maintenance recommendations for system
electronics and identifies design changes.
The EPRI guide Steam Turbine Hydraulic Control System Maintenance Guide, TR-107069, [5]
has been developed to improve the reliability of system hydraulic components and fluid through
maintenance recommendations. The results of the guide can serve as a valuable source of
information for plant personnel who are evaluating their hydraulic system to determine how to
improve performance.
The EPRI guide EHC Tubing/Fittings and Air Piping Applications and Maintenance Guide,
1000935, [2] was developed to deal with the tubing, fittings, and air piping in the steam turbines
that can be a cause of plant trips, load reductions, and maintenance problems. The guide
identifies causes of tubing, fitting, and air piping failures and also recommends maintenance
practices that will improve their reliability. Utilities can use the information provided in this
guide to identify causes of failures and implement maintenance practices that will improve the
reliability of the components.

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2.6.2 Waste Products to Be Considered
Epoxies are used in a variety of locations in the construction and maintenance of both the turbine
and generator. The generator typically has the most and widest use of epoxies and other materials
where waste products are at issue. Within the generator, epoxies are used in the assembly or
reconstruction of stator end winding liquid connections. Epoxy paint may be used to seal joints.
The epoxy and its solvent require special handling during processing. Waste products may
include mica, fiberglass, epoxy, and absorbents from cleanup. Often, the liquid waste can be
more easily handled by mixing the remaining components together to form a solid product.
Waste handling can be done by incineration or landfill disposal in accordance with local, state,
and federal regulations.
2.7 Crane Availability
Most components associated with a turbine-generator outage require lifting devices to assist in
their disassembly, handling, transport, repair, alignment, and reassembly. Therefore, having
sufficient resources and coordination of these lifting devices is essential to a successful outage.
There are three important phases of overhead crane usage during an outage:
Phase 1 Disassembly: Depending on the utility, one or two overhead cranes may be
available for use during disassembly. It is important to plan disassembly and required vertical
lifting clearances so that a crane does not become load locked, that is, lifting a load and
having to wait until another crane moves; this increases the outage time. Not only is
coordination of usage essential but also the sequence of use.
Phase 2 Overlap during disassembly: The second phase is the transportation or moving of
components for cleaning, NDE, or repairs. This phase will usually overlap the disassembly of
other components. Components should be initially set once during disassembly and then
prepared for lifting/transport for the next phase of activity. It is best, but not always practical,
to lift once and to set/load for the final destination. Having multiple lifting systems
appropriately located during the outage facilitates this phase of activity.
Phase 3 Assembly: The final sequence is assembly. The same disassembly concerns apply
to reassembly; improper hook or overhead clearances during assembly can load lock a load
and delay assembly.
Other concerns for coordination of crane usage during an outage are associated with non-turbine-
generator requirements. Often, the turbine deck overhead crane will be required to support non-
turbine deck activities. Non-turbine deck requirements should be planned and coordinated before
the outage begins. This allows for the integration of the other activities into the turbine-generator
outage plan. Outage support activities usually begin at least one week before the start of the
outage. During this time, the utility uses the overhead crane to pre-stage turbine-generator outage
support equipment. This is an ideal time for vendor support equipment to arrive at the station and
be transported to the turbine deck and work centers as appropriate. Lifting beams, lifting eyes,
lifting slings, and cables used during an outage should be inspected by NDE before the outage.
The critical components should be inspected before each outage and visually inspected before
each use. Less critical items should be on a periodic inspection schedule.

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The proper operation, testing, and maintenance of overhead gantry cranes can contribute
significantly to improved reliability and safety and to the avoidance of costly downtime. The
EPRI guide Crane Maintenance and Application Guide: Maintenance and Application of
Overhead Cranes, 1000986, [6] includes detailed component information, in-depth overhead
bridge crane maintenance practices, and inspection programs for different types of cranes.
2.7.1 Crane Maintenance to Be Performed in Advance
Normally, turbine deck overhead cranes accumulate minimal usage hours throughout the year
but are constantly used during an outage. Outage preparation is necessary to ensure safe and
reliable operation during the high usage period . An out-of-service overhead crane can severely
impact the schedule. All critical lifting devices should be load tested prior to the outage. This test
checks the capacity and operating components of the lifting device. The hook should also be
NDE inspected before the outage and as part of the load test. The crane rails should be visually
inspected before the outage. Any abnormalities should be addressed.
2.7.2 Types of Cranes
Lifting device selection during an outage will be dependent primarily on weight and reach. A
central lifting device can be used that has reach capability and relieves some of the overhead
crane use. Often, the primary lifting device to remove turbine-generator components is the
overhead crane, which is later supported with other strategically located lifting devices in the
work center areas as shown in Figure 2-14. On most outdoor turbine-generator installations, a
large gantry crane is the primary lifting device.

Figure 2-14
Types of Lifting Cranes
Table 2-18 offers alternatives for lifting turbine-generator components. Note: The component
weight and lift orientation determine the right lifting device.

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Table 2-18
Alternative Lifting Devices for Turbine-Generator Components
Component Overhead Picker Jib Gantry
Bearings - in place
x

x
Bearings - repair area
x x

x
Bolting
x x

x
Crossovers
x

x
Diaphragms
x x x x
Generator end shields
x

x
Generator field
x

x
Miscellaneous parts
x x x x
Packing heads/casings
x x

x
Rotors
x

x
Shells, casings, hoods
x

x
Valve components - in place
x x x x
Valve components - repair area
x x

x
2.7.3 Crane Use Schedule
An effective crane use plan is made up of a number of elements. The first and most critical
element is a person assigned to coordinate all crane activities at least during the crucial times of
turbine-generator assembly/disassembly. Multiple personnel will vie for crane usage and,
without a coordinator, will soon create scheduling and sequencing havoc.
Another element is involvement with the current sequence of turbine-generator activity that is
linked to the outage schedule. Crane usage may be noted either on the schedule directly or by
association to component activity description such as remove.
The next element is having a detailed lay-down plan, so that when an item is removed, it can be
positioned once and not have to be moved to facilitate locating another component. Having racks
and stands pre-staged complements a single lift and set. It is also necessary to coordinate floats
(truck trailers) if they are to be used for loading turbine-generator components from the turbine
deck to other locations for sandblasting, NDE, repairs, or other activities.
2.8 Turbine Deck Lay-Down Planning
The turbine deck lay-down plan is a map for component placement during the disassembly of the
turbine-generator. The turbine-generator is made up of thousands of parts, and when
disassembled, the parts can be scattered over thousands of square feet of floor space (and across

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acres of space if the removed components are placed off the physical turbine deck). Like any
map, it is a useful tool for providing location information. Therefore, it is essential that the plan
be followed when placing components. The map not only provides logistical information but
also, depending on the turbine deck construction, may act as a guide for safely placing heavy
loads that are removed from the turbine-generator onto the turbine deck or other surfaces. Unlike
roadmaps, the turbine deck lay-down plan can be modified and the modifications registered
during an outage.
2.8.1 Basic Elements for Any Deck Lay-Down Plan
The turbine deck lay-down plan is a valuable tool for use by all personnel associated with the
turbine-generator outage. Each group may interact with the lay-down plan in a different manner
but share in its use as a communication tool. Consequently, the elements that make up the plan
must meet the interactive needs of those associated with the turbine-generator outage.
Consideration should be given to the work being performed on the components removed from
the turbine-generator. Like activities may be grouped into work centers. A work center should
provide all the requirements within the concise location to perform the job. Arrangements to
meet any unique or specific job plans should also be included.
A standard template for the lay-down plan should be created. The template will contain the
information that is static for each outage. The template should be created as a layer within a
drafting program, and each outage can be created on top of the template as a separate layer.
Disassembly consistencies, work centers, etc., may also be contained on the template layer or on
a layer unique to each. Similar components can also be color coded so that they can be easily
distinguished. Part orphaning can be easily detected on a computer monitor during the
planning phase. Printouts from a color printer or plotter can also indicate the visible component
groupings and show potential interferences on the turbine deck. The following list details the
type of information that should be included in the template for a lay-down plan:
Grid references distances/column coordinates/plant reference/orientation
Plant equipment outlines
Fire lanes or other safety zones
Support facilities - rest rooms/cafeteria/lunch rooms
Floor loading requirements - uniform loading/point loading
Special component lay-down information
Component - footprint/weights/identification - color coding
Lifting resource locations, other than an overhead crane
Overhead crane limitations and hook location restrictions
Power voltage/phase/amperage/feed panels, breaker locations, etc.
Compressed air supply locations

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Floor drain locations
Water locations potable/service
Tools tool room/slings, cables, etc.
Work centers (permanent) identification/storage/work area/support equipment/component
racks/component orientation
The outage plan includes the component lay-down locations for that outage, including any
unique outage activity requirements. Routine outage work must be integrated with any unique
outage activities, both from the turbine-generator and from any other area of the plant.
Component grouping and lay-down location should take into account the following:
Setting orientation should consider activities to be performed including scaffolding and
repairs
Example: machining of the main steam lead flanges of the HP outer shell. This requires a
shell orientation where scaffolding can be erected for access to the flanges with sufficient
room to machine the flanges without limiting access to other areas of the shell.
The total area required to perform any maintenance on the item, including the footprint of
component, access areas around the component, work tables, support equipment, and other
things.
Example: replacing the last stage bucket on an LP rotor. Encroachment can occur into the
repair area if not properly planned, especially if the rotor is set early in the outage, before the
bucket work begins. Having a plan that identifies all the area required will help prevent
having to rig and re-rig components to make floor space available to perform the actual
maintenance.
Loading interaction with other components
Example: the performance of a generator field rewind that will require a special area with
unique floor loading requirements, access to support equipment, and floor spacing to
construct a clean room. Generator fields provide a high density floor loading; therefore,
proximity to other components and equipment may require a total section floor loading
evaluation.
Outage sequence dependent lay-down utilization
Example: performing rotor bore inspections. The rotor bore inspection is usually performed
early in the repair cycle when turbine deck space is at a premium. Approximately double the
rotor length space is required in order to perform the inspection. Because the inspection is
usually short, that deck space may be recycled quickly.
Safety considerations
Example: slow-speed balancing turbine rotors on the turbine deck. Location, weight, safety,
contamination, and outage sequence are all considerations when planning the location for the
lay-down plan. Rotating rotors at slow-speed balancing speeds require area access control.

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Example: application of thermal spray coatings such as high-volume oxygen fluid (HVOF)
process on diaphragms. Acoustic energy produced during the HVOF may cause noise
pollution concerns for those on the turbine deck.
The following lists of some information that should be considered when planning for unique
activities:
Work centers (temporary)
Footprint
Utilities
Storage and lay-down space for component pre-assembly or disassembly
Support equipment
Arrival date
Utilities
Setup information
Expected activity dates
2.8.2 Basic Items or Issues to Be Reviewed
If a turbine deck template containing all the static information has been created, the pre-outage
review and planning can focus just on the upcoming outage, including both the routine and
exceptional activities. If the lay-down plan has been created in a drafting program with layers
assigned to the work centers, routine component locations, and other areas, the review can start
with those.
Identifying any unique work for items typically assigned to the routine plan will cause those
items to be pulled from the routine plan. They may either be set on separate layers within the
drafting program or keyed with another color. Comparing the outage disassembly plan and the
repair scopes for the remaining components will identify any other lay-down areas that might
require modification.
Consideration can be given to traveling distances, first selecting the location and other
subsequent variables to meet both the special and routine requirements for a component. A
component can be broken out from its normal setting location to perform the special activity on it
and then returned to its routine location.
Therefore, the review sequence checklist is:
1. Identify unique or special jobs to be performed.
2. Remove those items from their normal location.
3. Evaluate special job requirements and available turbine deck space.

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4. Shuffle the components to accommodate special activities.
5. Rearrange routine location items to accommodate as necessary.
Note: The number of components removed from the turbine-generator and the space to place
them is a constant. The variables are support equipment to perform special activities and the
timing sequence within the outage. Therefore, the lay-down plan is a dynamic jigsaw puzzle to
be solved for each outage.
2.8.3 Items to Amend in a Customized Plan
The first draft of the turbine deck lay-down plan should be issued for review before the outage.
All groups involved with the turbine-generator outage should review the initial draft. This review
includes other maintenance plans from other work areas if they affect turbine deck usage. All
comments and suggestions should be reviewed and implemented as appropriate. One last review
should take place during the pre-outage meeting. A typical pre-outage meeting can be held
within a month to two months before the outage. All turbine-generator work should be locked in
prior to the pre-outage meeting so that final revisions can be made to component location, work
center details, and other items.
2.9 Special Tools, Equipment, and Facilities
An important utility component is its compressed air system. It is needed to operate air tools in
the maintenance shop and in the plant; it operates pneumatic controls of air-operated valves, air-
operated solenoid valves, etc. Companies will install, operate, and maintain a compressed air
system on-site to provide required compressed air. Unit reliability and energy costs are affected
by the system performance. The EPRI guide Compressed Air System Maintenance Guide,
1006677, [7] provides information for plant maintenance and operations personnel on how to
maintain system reliability, which ensures that the system is functioning as required. It identifies
corrective, preventive, and predictive maintenance that can be implemented to improve system
performance and also troubleshoots system problems.
Nondestructive examination (NDE) is an integral part of every turbine-generator outage. The
simplest and most often used form of NDE is visual inspection. NDE is used as an investigative
tool during a turbine-generator outage to assist in the determination of the repair scopes for
components. NDE is performed to identify indications, abnormalities, and discontinuities of
components. It is the responsibility of the turbine engineer to evaluate the NDE result and outline
the scope of the repair. Not all NDE indications require repair, but all NDE indications require a
disposition. The disposition made may be return to service as is, repair, or replace, but a
determination must be made. Many forms of NDE are available to the turbine-generator
engineer; each is a unique tool that may be used alone or in conjunction with another to provide
component condition. The items that follow list NDE methods and processes available and
normally used for turbine-generator maintenance inspections:
Magnetic particle (MT) AC/DC/dry power/wet fluorescent
Liquid penetrant (PT, red dye)

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Ultrasonic (UT)- straight beam/shear wave
Eddy current
Video CCTV/cameras
Radiography (RT)
Replication creep/stress corrosion cracking (SCC)
The use of each process may require planning and coordination during an outage. Most are
unobtrusive to the turbine-generator maintenance being performed; however, RT is one process
that must be planned and coordinated if it is being performed on the turbine deck. RT can be
scheduled for off shifts, lunch breaks, and other times when the impact on workflow can be
minimized.
Processes such as replication may be used more on older machines than newer ones, as time-in-
service-dependent damage begins to occur. Other processes such as UT may have more schedule
impact than others when applied to rotor inspections.
All forms of NDE require some form of surface preparation. Sometimes, it may be only wiping
the oil or dirt from the surface so the component can be viewed. Other cases may require actually
etching the surface of the metal to enhance indications. The most used process during the outage
is MT (both wet fluorescent and dry particle), followed by PT and UT. The other processes are
used as appropriate.
Testing is a significant portion of a generator outage. Todays generator tests tend to focus on
two areas:
Insulating system test
Water cooled stator winding integrity test
Of the two tests, the stator winding integrity test requires equipment that makes use of more
turbine deck space around the generator. For this test, skid-mounted equipment is employed to
dry out the stator windings by using pressurized air to blow contamination/particles from the
windings and a vacuum to boil off any remaining moisture. The skid is then utilized to test the
hydraulic integrity of the stator windings.
Special care is required when the generator field is removed from the stator for inspection or
repair. It is not only important to protect the field from moisture and contamination but also from
using the wrong types of solvents, cleaners, or inspection media. Ideally, when the rotor is
removed from the stator, it is maintained a few degrees above ambient temperature to prevent
water vapor from condensing on the generator parts. Constructing a wood-frame, visquine-
(plastic) covered enclosure over the field while it is removed from the stator and on the turbine
deck is one method of protection from the environment. The enclosure should be constructed
with sufficient room to perform inspections and limited maintenance. Using an enclosure can
also limit access to the field, helping to ensure cleanliness. A lengthy and tedious process may be
required if dryness and cleanliness are not maintained during the outage.

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2.9.1 Storage and Work Space Provisions for Cleaning and/or NDE
NDE may be performed in a variety of locations during a turbine-generator outage. Sometimes,
components will be inspected at a central location. Normally, NDE is performed in place on
large components such as rotors and shells or where they have been set. NDE may also be
performed in work areas or work centers where it is easier to bring the NDE to the part than vice
versa. This condition would include items such as bearings, etc. Smaller components such as
fasteners or fan blades will be done at a central location.
Temporary structures may be required both for cleaning and for NDE. Grit blasting is done in
some locations on or near the turbine deck. In these cases, temporary enclosures are erected with
exhaust and collection systems to handle the grit dust. The preferred location for grit blasting is
away from and off the turbine deck; however, in some cases, grit blasting must be done on or
near the turbine deck. For example, when the valve chest must be blasted for NDE, the choices
are limited to working on or near the turbine deck. The valve area must be enclosed and an
exhaust collection system used. It is advantageous to locate the exhaust system and filter bag
(collection system) off the turbine deck. This will help prevent depositing the small uncollected
grit dust onto the turbine deck and components in close proximity.
Other methods of cleaning may be performed on the turbine deck. Part cleaners and temporary
cleaning areas may be designated where wire brush and abrasive cleaning is done. On larger
components, the cleaning is completed where the component is set.
Grit blasting and cleaning generally require well-lit areas, but a light-limited environment is
required when doing wet fluorescent magnetic particle inspection. Temporary frames covered
with black 35 mil (0.07620.127 mm) plastic may be sufficient for small areas. Large portable
or permanent structures are required for larger components. Some components require that
scaffolding or pre-constructed structures be erected for both cleaning and inspection. Outage
planning may be required to coordinate activity in the larger facilities if they are used for
multiple activities during the outage.
2.9.2 Provisions for Cleaning and Inspecting Different Turbine Parts
Cleaning is required to remove insoluble deposits on various turbine components. The purpose of
cleaning of a component may be just to remove surface deposits to facilitate inspection, or
cleaning can be focused on the removal of deposits that are causing a reduction in turbine
efficiency. In either case, the purpose of cleaning is never to damage the component through
excessive material removal or by leaving detrimental surface conditions, such as scratches or
gouges, that might affect the fatigue strength of the component. Therefore, it is not only
important to remove the surface masking deposits but also not to damage the part in the process,
so selection of the appropriate cleaning method is important.
The most commonly used method of cleaning is grit blasting. Grit blasting is economical
because it is thorough and faster than most any other cleaning process. It also provides uniformly
cleaned surfaces that are an aid to NDE. It is also aggressive and can remove tough surface
deposits.

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Typically, 220-grit alumina oxide (other materials are also acceptable) is used to remove surface
deposits from the turbine steam path, shells, casing fits, horizontal joints, bolting, valve pressure
seal heads, gasket fits, and other items. Depending on the quantity and toughness of the deposits,
anywhere from several hundred pounds to a ton of oxide may be used to clean turbine
components. The oxide may be reused after screening to remove foreign objects that might
damage the turbine component. The oxide particle size and cutting edges are changed as the
oxide is used. The change in size and loss of cutting edges make the oxide less aggressive; this
change is advantageous when doing fasteners.
The blasting media for the rotor bucket/blade attachments is glass beads. Glass beads are less
aggressive than oxide and pose a lower chance of material removal. Glass beads leave a very
smooth finish; therefore, it is important to identify the scope of work and the type of blast media
required, especially for any bucket/blade removals.
Methods of local cleaning include:
Hand stoning - used to remove oxide buildups from turbine-generator fit-up areas that cannot
be grit blasted. Soft stones, such as griddle stone, are fast-cutting stones and are normally
used to clean the oxide scale from joints and fits. Harder stones, such as India Oil and
Arkansas stones, are used for precision work in finding burrs when a true flat stone is needed.
Strap lapping - used for both cleaning and surface preparation of bearing journal surfaces.
Strapping uses narrow emery cloth of at least one or possibly two different grits.
Wire brushing - used to clean smaller bolt threads, carbonized oil from oil deflector teeth,
etc. Wire brushing is not a method recommended for surface preparation for NDE. Wire
brushing smears the surface metal and may hide or mask indications.
Scotch-Brite pads and abrasives - used to polish or clean light, thin surface deposits
depending on the medium. Aggressive cutting discs may be used to prepare surfaces for
repair or NDE.
Chemical cleaning - used to remove oils, chemical surface deposits, and penetrants. Two
concerns are evident with chemical cleaning: will the product produce a hazardous waste and
what impact will it have on the component being cleaned. Use of the wrong cleaners may not
only have an impact on the environment, but also may attack the base material, causing
pitting, or contribute to SCC.
Outage planning should include a review of all the consumable items required to support in-
house cleaning of components.
Table 2-19 lists the NDE equipment for each process that is typically required as support for a
turbine-generator outage.

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Table 2-19
List of NDE Equipment Used to Support a Turbine-Generator Outage
Magnetic Particle Testing Liquid Penetrant Ultrasonic Testing
AC yokes with articulating
legs
Cleaner Flaw detectors
DC yokes with articulating
legs
Penetrant Thickness meters
Power supplies - large
applications
Developer Transducers
Cables Calibration blocks
Extension cords Couplant
Dry power
Wet fluorescent
Fluorescent lamp (black light)

Materials planned for the outage may be in bulk form or in smaller portable units. A review of
the outage plan will provide an insight into the scope of inspections required. From this review, a
comprehensive list of required NDE equipment and supplies can be developed.
2.9.3 Items or Issues Specified as Part of the Work Order for Vendors
A list of items that should be contained within the vendor work/purchase order for turbine-
generator NDE activities is provided here:
Scope of work: Comprehensive list of the components to be inspected. Component cleaning
responsibilities. Inspection process (for example, first, complete visual, then). Component
marking
Contractor/vendor-supplied materials and equipment
Utility-supplied materials and equipment
Commencement and expected completion dates
Work force loading and shift requirements
Daily reporting and timekeeping
Documentation: NDE personnel certifications. NDE personnel eye exams. Current
equipment calibration NDE procedures
Rates
Office: space, computer and printer
Safety equipment and requirements

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Inspection standards: OEM inspection standards, utility turbine-generator inspection
guidelines
Communication: findings notification process, report format, rough and final, disposition
process, schedule, priorities, and direction updates
Chemicals: MSDS, handling and disposal
2.10 Machine Disassembly Plan
Effective turbine-generator disassembly begins with planning months before the first fastener is
removed. Physical activities supporting machine disassembly begin during the pre-outage period
that is usually one to two weeks before the outage. The disassembly plan should not only include
the setup or staging activities and actual disassembly but also take into account reassembly and
post outage activities. The machine disassembly plan also includes methods for disassembly,
identification, and determination for alternative disassembly/reassembly methods. Resource
planning is also an element of this plan. Add in the work scopes, and all the ingredients
necessary to develop a plan are present.
2.10.1 Basic Elements in the Machine Disassembly Plan
The sequence for the removal of turbine-generator components is the central element of the unit
disassembly plan. Inputs from defined work scopes, logical or norm disassembly processing,
work force availability and quantity, and facility resource availability shape the disassembly
sequence.
Defined work scopes may place an emphasis on a particular section to be disassembled, but the
normal disassembly sequence and data collection may delay the disassembly work on that
section. Limitations in both work force and facility resources may also affect the actual
disassembly sequence.
2.10.2 Issues or Items Reviewed
The following is a list of items that should be reviewed as part of the outage plan:
Schedule
If the outage is properly planned, the schedule becomes an accurate guide or roadmap for the
outage. Even the best-planned outage will often have unexpected damage found that requires
repairs. These activities are generally unplanned for and may, if not properly addressed,
affect the outage duration.
The schedule should be constructed of the activities that are performed to components that
make up the turbine-generator. These activities are assembled into a logical manner
reflecting the disassembly, repair, and reassembly of the turbine-generator. These activities
should be constructed into groups or modules. Each group or module is a self-contained
unit with branches or links to other modules as appropriate. Alternative modules can be

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pre-constructed and developed for what-if scenarios. These what-if modules can be
inserted into the schedule when the time comes to accommodate the unexpected. Instead of
many unguided paths arising from an unexpected repair, a predetermined integrated plan of
action is now ready. An example of a shift in action is the result of stuck coupling bolts that
cause resources to shift slightly and redirect the flow of disassembly.
Ensuring that all component modules are completed (with all the elements and activities
identified) is the primary focus of schedule planning. A second planning activity is the
development of alternative modules that can be used to address unplanned but potential
disassembly problems.
Resources
Certain resources are limited during any maintenance outage. Limits on these resources will
impart constraints on the disassembly and can have a significant impact on the overall
schedule if not properly addressed.
Review the historic actual hours, craft types, and other resources that were logged in to
complete previous outage activities. A review of work force` loading for the upcoming
outage, including work load and craft distribution, is essential as the schedule develops. It
may be beneficial to extend the workdays of the disassembly personnel to expedite
component exposure. Ensure that the correct number of qualified personnel on the
appropriate shifts are available to support the outage including supervisors, mechanics, craft
personnel, and engineers.
A review of quantities of tools and equipment and the state of repair or status of tools is part
of the disassembly preparation.
Work Packages
A work package should contain all pertinent information of what is to be completed, how it is
to be completed, by whom it is to be completed, and with what resources it is to be
completed. This is important so that a smooth transition from disassembly to work package
implementation can be made.
Disassembly/Reassembly Methods
Disassembly activities include not only removing fasteners and moving iron but also taking
measurements and performing alignment checks to both assess the current machine condition
and identify items to be addressed. A review of the disassembly plan should contain the
appropriate rotor position checks, rotor clearance checks, coupling alignment checks, and
bearing clearance checks before rotors are removed.
Optional plans should be prepared for exceptions or problems during disassembly. Plans
would include alternative vendor resources and additional equipment so that if an
emergency arose, it could be handled expeditiously.

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2.10.3 Identifying Contingency Plans for Unexpected Work
The types of problems that are normally encountered during disassembly often involve fasteners.
Stuck fasteners can be at any location along split lines: shells, diaphragms, valves, and coupling
rotors. Having one stuck fastener can delay disassembly if alternative removal methods have not
been prepared. The most often used method is to air-arc off the resistant fastener component.
Occasionally, shells can stick because of galling on fitted areas or distortion from water
induction incidents and may require additional parting resources.
Potential disassembly problems should be investigated before they happen. The plan to address
problems should include not only resource options but also an agreed upon if-then decision flow
process. This will reduce delays during disassembly.
2.11 Foreign Material Exclusion
Like it or not, gravity exists, and anything dropped always seems to fall into the most unlikely
locations in a turbine. Around a turbine-generator, dropped objects will find their way to the
lowest and the most difficult locations from which to be extracted. Therefore, the best foreign
material exclusion (FME) plan begins with attempting to defy the laws of nature by not giving
them an opportunity to be demonstrated. An FME plan should consist of three items:
Prevention
Documentation and notification
Extraction
The foreign material that enters a system can cause equipment degradation or inoperability,
andfor a nuclear stationfuel cladding damage, spreading high radiation and contamination
levels throughout the plant. As a result, great care and strict precautions must be taken to avoid
the introduction of foreign materials into plant systems. To present a proactive approach to
preventing foreign materials in a plant, the EPRI report Foreign Materials Exclusion Guidelines,
Revision 1, 1009709, [8] has been developed. The report provides a comprehensive overview of
the technical considerations required to develop, implement, and manage an FME program at a
nuclear power station; however, much of the information in this guide is directly applicable to
establishing an effective FME program in a fossil station.
In addition to the EPRI report cited in the previous paragraph, programmatic guidance is
provided in Appendix D of this report. Appendix D compiles many good practices and lessons
learned from plant and site personnel and should be considered if developing or enhancing an
FME program.
2.11.1 Organizational Responsibilities for Turbine-Generator Contracts
Prior to performing any work on the turbine-generator, responsibilities should be assigned so that
the likelihood of foreign material intrusion is minimized. Appendix D.3 of this report provides
additional guidance from a programmatic perspective. However, it may be beneficial to establish
organizational responsibilities specifically for contracts related to work on the turbine-generator.

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Figure 2-15 illustrates a typical organizational structure for assigning and implementing the
responsibilities described in this section.

Figure 2-15
FME Organizational Structure for T-G Contracts
In these instances and as described in Figure 2-15, some utilities have established the following
positions and related responsibilities:
2.11.1.1 Turbine-Generator Contract Technical Coordinator
The turbine-generator contract technical coordinator (CTC) typically reports to the project
manager and has the following responsibilities:
Plans, sets up, and executes the Foreign Material Exclusion (FME) program for all zones of
the turbines, generator, main steam valves, and auxiliary systems that present a potential
threat for the introduction of foreign material into the turbine-generator system
Communicates the foreign material control program requirements to plant personnel and
contractor personnel who are working on the turbine deck
Ensures that periodic surveillance is conducted of the FME zone to make sure that good
engineering practices are implemented in support of this program
2.11.1.2 Contract FME Engineer
The contract FME engineer typically reports to the CTC and has the following duties:
Serves as primary assistant to the CTC for technical matters relating to the FME program.
Ensures that the contractor sets up the turbine deck using the recommendations contained
within this performance guide.

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At the direction of the FME lead, ensures that FME zones are clearly identified and
adequately segregated from the work zones.
Ensures that the requirements of this performance guide are complied with by all contractor
staff and in all FME zones.
2.11.1.3 Lead Foreign Material Exclusion Monitor
The lead foreign material exclusion monitor (FMEM) typically reports to the plant CTC and has
the following duties:
Serves as primary assistant to the CTC for matters relating to the execution of the FME
program requirements
Directs the FMEMs in the execution of their assigned duties and acts as their first line
supervisor in the execution of the FME program
Ensures that supplies and materials are available to perform all FMEM duties
Is the primary means of supplying necessary FME zone training and providing management
oversight in the enforcement of FME requirements for all FMEM personnel who have
assigned duties in the FME zone
Conducts all training for the turbine-generator team on FME zone operations
Assists the FME engineer with craft training of FME policy and procedures
Prepares and administers the work schedule for the rotation of duty FMEMs
Upon completion of the FME zone audit and after completion of the outage, turns in all FME
zone records to the FME engineer for review
Ensures that FME paperwork gets put into the work package for processing FME records to
the RMS for the life of the plant
2.11.1.4 Foreign Material Exclusion Monitor
Foreign material exclusion monitors (FMEMs) typically report to the plant CTC via the lead
FMEM. An FMEM often has the following responsibilities:
Serves as entry log monitor
Assists both primary and secondary monitors, rover position
Assists with observing craft upon ingress and egress
Assists with craft/guest personal possession process upon ingress and egress
Provides observation support in FME area zone 2
Relieves primary and secondary monitors for rest and lunch breaks
Supplements supplies necessary for FMEM duties

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An FMEM often has the following duties:
Ensures that the recommendations of this performance guide are used within all FME zones.
Ensures that all personnel who enter the FME zones have been approved for entrance and
have signed the FME zone Rules Form.
Completes the required FME documents such as the permanent parts storage log, long-term
tool and material storage form, daily tool and material entry log; and any other forms deemed
appropriate by the turbine-generator CTC for all parts, tools, and other materials that enter
into or are removed from the FME Area.
Ensures that personal belongings such as jewelry, wallets, coins, watches, pens, and pencils
are removed prior to entering FMEA zone 1 (Exception: wedding rings).
Ensures that FME zone 1 is secured by lock or personnel during periods of no work. FME
zone 1 will be monitored when personnel are assigned to work during lunch periods and
assigned breaks or when personal belongings are unable to be secured under lock and key.
Advises the CTC (or their designee) and the FME engineer on the effectiveness of the FME
zone security system.
Ensures that the daily audit of tools is completed and signed by the FME engineer prior to
leaving the turbine deck at the completion of the shift.
Controls all personnel access and egress to the FME zone.
Controls the master turbine-generator drop list and ensures that each drop is recorded.
Immediately after a drop is recorded, it should be reported to the engineer responsible for the
equipment.
Periodically walks down the FME areas to watch for unattended tools, materials, or trash.
Provides a physical presence during fire watch/confined space entry/escort.
2.11.1.5 Personnel Assigned Duties Within the Turbine-Generator FME Zone
In general, personnel performing duties within the turbine-generator FME zone typically have
the following responsibilities:
Clearly understand that it is each persons responsibility to understand and comply with the
FME zone rules.
Ensure that the recommendations of this performance guide are used while inside an FME
zone.
Ensure that prior to entering the FME zones they have been approved for entrance and have
signed the FME zone Rules Form.
Provide the FMEM any assistance required in filling out the required FME documents such
as the permanent parts storage log, long-term tool and material storage form, daily tool and
material entry log; and any other forms deemed appropriate by the turbine-generator CTC.

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Be familiar with the general requirements for the protection of turbine-generator equipment
or systems during disassembly and reassembly if their duties include assembly and
disassembly of this equipment that could involve a potential FME incident
View any appropriate FME training material (for example, the video tape Generator Job Site
Control) prior to beginning work in that FME zone.
2.11.2 Areas of the Turbine-Generator to Protect
Appendix D.4 of this report provides general guidance for establishing and implementing FME
program requirements. Specific to turbine-generators, the following guidance should be
considered when determining the areas of the turbine-generator to protect and subsequently in
developing requirements to protect them.
Damage to the rotating element and subsequent stationary components are what an FME plan is
trying to prevent. Almost anything lodged in the steam passage can be broken down over time.
Fragments are then transported by the steam flow and ultimately contact the rotating components
where they either do damage or are accelerated and do damage to the stationary components of
the steam path.
Foreign objects left in the air gap (space between the field and the stator core) and non-metallic
items can block ventilation areas, but conductive objects can cause shorting of the core, leading
to failure and restacking of the core and rewinding. Magnetic material can be influenced by the
rotating magnetic field, accelerated up to operating speed, and flung offcausing damage in
multiple regions before finally becoming wedged at some location. Objects left in the generator
end windings may cause chafing from vibration or flutter, ultimately cutting through insulation.
Foreign object damage (FOD) in bearing oil or hydrogen seal feed lines will do similar damage
to either the stationary or rotating components; damage will occur when the fragments are forced
through the tight clearance. Not all lines lead into the turbine; extraction and steam seal lines
may lead to other components that can be damaged by items dropped or left in the lines. Items
can be transported and lodged in a valve, preventing operation at a critical time. Understanding
the piping routing, machine components, and possible damage scenarios helps to identify the
critical areas that must be protected.
Some of the critical drop locations around a turbine-generator change with the state of
disassembly or reassembly. It is easy to extract a file that is dropped into the shell when the rotor
and diaphragms are removed, but extraction when the rotor and diaphragm are in place may
become a time-consuming challenge.

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Table 2-20 lists critical areas that should be protected.
Table 2-20
Areas of a Turbine-Generator to Be Protected During Disassembly
Area Potential Damage To:
Bearing feed lines Bearings
Journals
Extraction lines Non-return valve
Isolation block valve
Heater
Generator Stator end windings
Stator core
Field
Cooler bundles
Bushing boxes
Ventilation areas (ducts, passageways)
Hydrogen seal feed lines Hydrogen seal
Journal
Main steam lines Steam path
Reheat lines Downstream valve
Steam path
Shells Steam path
Extraction system
Steam seal lines Valves
Heat exchangers
Seal supply areas
Stop or control valve Down stream valve
Steam path

2.11.3 Measures to Take for Each Critical Area
The primary intent of a foreign material exclusion plan is prevention. Prevention planning has
three elements:
Educating personnel. FOD training should occur as part of the pre-outage training program.
Emphasis in training should include what FOD can do to a turbine-generator and how to keep
foreign objects out.

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Preventing items from being dropped. Simple exclusion plans include such items as
personnel emptying pockets before entering critical areas and tying off tools at critical times
of reassembly. Notification is essential if an item is dropped into the turbine. This includes
foreman/supervisor notification and logging the drop on a drop list. The drop list should
contain: the date, the name of the person who dropped the item, a description of the dropped
item, the location of the dropped item, and an extraction check off.
Preventing items from entering critical areas. A blocking device log should record when
every blocking device is installed and removed. If the blocking device is not removed, it can
also result in FOD in the unit. Table 2-21 lists suggested locations and types of prevention
that can be used.
Table 2-21
Areas of a Turbine-Generator That Should Be Blocked
Area Prevention
Bearing feed lines Use brightly colored duct tape. Silver duct tape is often used to cover
items, but this matches the color of the metal too closely.
Extraction lines Use plywood or metal covers. Continue to use the covers until after the
diaphragms and rotors are in place. Connect a brightly colored
extraction cord to each cover.
Generator Empty pockets.
Cover openings with plastic film/sheets. (See Note)
Hydrogen seal feed
lines
Use rags to stuff in the lines.
Use brightly colored duct tape. Silver duct tape is often used to cover
Main steam lines Place covers over the valve openings when no activities are taking
place.
Reheat lines Place covers over the valve openings when no activities are taking
place.
Shells Empty pockets.
Tie off tools when components are being reassembled.
Steam seal lines Use brightly colored duct tape. Silver duct tape is often used to cover
Use plywood or metal covers. Continue to use the covers until after the
diaphragms and rotors are in place. Connect a brightly colored
extraction cord to each cover.
Stop or control valve Place covers over the valve openings when no activities are taking
place.
Note: Avoid using black or red duct tape because these colors can easily blend in with red or
black colored turbine stator parts and can be overlooked when they need to be removed.

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2.11.4 Implementation of FME Plans for Turbine-Generator Work
Maintenance activities on the turbine-generator should be conducted with a plan to prevent the
intrusion of any foreign material. Appendix D.5 of this report provides additional guidance
regarding the development of FME plans. The following issues should be considered during the
development of FME plans for turbine-generator work.
2.11.4.1 Steam Turbine
Operating experience tells us that turbine components are considered high-risk FME areas. Rotor
blades tend to be susceptible to various types of damage due to foreign material intrusion. Flow
paths upstream of the turbine blades need to remain free of foreign materials. Working in the
vicinity of turbine bearings and coupling faces requires that the areas be controlled to prevent the
entry of foreign material.
In addition to the main steam paths of the turbine and the bearings, consideration should be given
to FME requirements for work on the stop and control valves, steam chest, turbines, electro-
hydraulic components, seal oil, and lube oil components of the turbine systems. The controls put
in place should include the completion of FME plans prior to the start of any work. These plans
should reference pertinent industry operating experience to prevent the chance of foreign
material intrusion.
2.11.4.2 Generator
Due to the size of the component and the large number of persons involved in generator
maintenance, the electrical generator is extremely susceptible to foreign material intrusion during
maintenance operations. Cases have been reported where plastic bags, metal-handled brushes,
and even large items, such as the skid tray used in extracting the generator rotor for maintenance,
have been left inside upon completion of the maintenance activity. Assignment of strict FME
control is recommended for the main generator area whenever the generator is open for
maintenance.
For major maintenance involving several work groups or exposing the generator internals,
establish physical barriers, and restrict access for nonessential personnel. Some plants erect metal
cages to restrict access to the unit.
Establish requirements for post-maintenance inspections immediately before closing the
generator. Consider flushing the cooling and lubrication systems to ensure that they are free of
debris.
2.11.4.3 Cross-Under Piping
Cross-under piping comes from the bottom of a high- or intermediate-pressure turbine cylinder
casing. Cross-under piping often has a sufficiently large diameter for items to be dropped into.
Prior to working in the areas of cross-under pipe openings, cover, dam, or seal these openings to

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prevent foreign material intrusion. After the completion of the work, remove the covers, dams, or
seals, and inspect the cross-under piping visually. Use a video probe or borescope, when
available. Consider using material accountability logs during work in these areas. Develop an
FME plan prior to beginning work.
2.11.4.4 Condensers
Condensers are common places to find foreign materials. Any time that a turbine, turbine
component, or piping is opened, allowing access to the condenser, the shell side should be
inspected prior to closing to ensure that no foreign material is present. Consider covering the
tubes under work areas such as extraction lines and expansion joints.
The controls put in place should include the completion of FME plans prior to the start of any
work. These plans will reference pertinent industry operating experience to prevent the chance of
foreign material intrusion.
Where water boxes, such as cooling water condensers or heat exchangers, have been opened for
cleaning, ensure that a thorough water box and tube sheet inspection has been performed prior to
closure. An FME plan should also be considered prior to beginning this type of work.
2.11.5 Performance of Work Inside the Turbine-Generator FMEA
Appendix D.6 of this report provides general guidance for performing work inside a foreign
material exclusion area (FMEA), with emphasis on the need for cleanliness before, during, and
after maintenance activities, as well as using graded FME controls. The following guidance
should be considered when performing work on the turbine-generator. Table 2-22 describes a
number of actions that should be taken to prevent the intrusion of foreign material into the
turbine-generator.

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Table 2-22
Example of FME Measures During Turbine Disassembly and Reassembly
Courtesy of FirstEnergy
Step Description of FME Action
1 All steam inlets, valve bodies, extraction ports, and oil lines that are opened for
maintenance purposes during scheduled and forced outages must be temporarily
plugged until repairs and inspections are completed and reassembly is imminent.
2 Installation of FME plugs should be listed as specific line items or indicated as written
comments or notes on the appropriate work list line item, on the Turbine Area Outage
Shift Work List. The Work List should be generated by the assigned turbine engineer and
distributed to the shift foreman for job assignments and pre-job meetings with assigned
plant craft labor. Installation of FME plugs should also be described within the
Component Work Plan or Maintenance Work Order for the assigned work item.
3 The FME plugs that are to be installed should generally be prefabricated, tight fitting,
compressible polyurethane foam plugs; inflatable rubber, or rubberized fabric bladders;
and/or plywood covers made especially for the intended applications. The plugs should
have permanent handles for ease of manipulation and removal. FME plugs should be
available in various sizes and should be accessible from a dedicated material storage
cage or gang box to be located on the operating floor in close proximity to the work being
performed.
4 All FME plugs should have special, brightly colored 3/8" (9.5 mm) diameter nylon ropes
tied to the plugs. The ropes should extend outside the turbine cylinders, shells, bearing
pedestals, reservoir, or structures and should be tied-off to a rigid fixture such as
permanently installed pipe, horizontal joint stud, or shell tie-off point. The intent of this
feature of this procedure is to provide a tell-tale, that is, to provide a physical means of
communication signifying that there are FME plugs present in the turbine component
being inspected and/or repaired.
5 The tie-off ropes should have special, brightly colored inventory tags that are attached to
the ropes. Inventory tags should be available from within the dedicated FME material
storage cage or gang box. Each FME plug should have its own separate tie-off rope and
inventory tag. FME plug inventory tag numbers should be written into a log, to be located
in the FME material storage cage or in the turbine engineers office. The FME log should
contain the inventory tag number, a description of the plug location, the date that the
FME plug was installed, and the date that the FME plug was removed.
6 It is the responsibility of the plant maintenance personnel performing the disassembly of
the turbine components to install the appropriate FME plugs into all ports, orifices, and
openings that are associated with the assigned disassembly. Installation of the FME
plugs will include tying off the plug with the special nylon rope, installing the inventory
tag, and logging the location and date of FME plug installation.
7 It is the responsibility of the assigned turbine engineer to identify the ports, orifices, and
openings that will require FME plug installation. In the event that the turbine engineer for
FME protection has not previously identified an opening, orifice, or port, it is expected
that the lead maintenance person working on the assigned turbine project would bring
this condition to the attention of the foreman and/or turbine engineer.

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Table 2-22 (cont.)
Example of FME Measures During Turbine Disassembly and Reassembly
Step Description of FME Action
8 Temporary removal of the plugs for maintenance activities may be required. In this event,
the FME plugs should be replaced at the end of each shift, providing that replacement of
the plugs does not cause harm or rework for the maintenance activity. If the FME plug
cannot be replaced at the end of the shift, the lead maintenance person should so advise
the foreman and turbine engineer.
9 Prior to reassembly of the turbine components into which FME plugs have been installed,
the assigned maintenance personnel should remove the FME plugs. Removal should
include returning the plugs, ropes, and identification tags to the FME material storage
cage and also recording the date of removal into the FME log.
10 Prior to reassembly of the turbine components for which FME plugs have been required,
the ports, openings, and orifices should be visually inspected by either the lead
maintenance person, the foreman, or the turbine engineer to ascertain that the FME
plugs, ropes, and identification tags have been removed.
11 Additionally, prior to reassembly of certain critical turbine components, such as steam
inlet lines, extraction ports, and main oil pump suction and discharge lines, these lines
should be inspected by video borescope by qualified NDE personnel, in order to
ascertain that no potential injurious materials have been inadvertently left in the lines.
Identification of the application of video inspections should be the responsibility of the
foreman or turbine engineer.

Appendix D.6.9 of this report provides general guidance regarding the use of FME devices,
including plugs when performing work inside the FMEA. The following guidance should be
considered when performing work on the turbine-generator. The list that follows
1
describes
various locations on the turbine-generator where plugs may be useful in minimizing the intrusion
of foreign material:
Main steam inlets following the removal of HP and IP upper-half outer cylinders or shells.
Since these line ports are typically positioned well above and away from the turbine
centerline, a short (1218" or 30.546 cm) tell-tale rope can be used, and it does not need
to be tied off. Instead, let the tell-tale ropes (and ID tags) hang down from the steam lead
ports.
Cold reheat ports following the removal of the HP upper half outer cylinder or shell. These
ports are typically large bore and located in either end of the lower-half outer cylinder. These
ports require the use of inflatable bladders or plywood covers. Tell-tale ropes (and ID tags)
should be extended above the horizontal joint (HJ) and tied off to a permanent fixture outside
the turbine shell.

1

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Main steam inlets following the removal of the lower-half HP and IP inner cylinders. These
ports are usually located near the axial centers of the turbine shells at the bottom of the outer
shell. In the case of SA-1 and SA-2 HP-RH sections, these ports are exposed after the
removal of the flanged lower shell inlet elbows. Tell-tale ropes and ID tags should be
extended above the HJ and tied off outside the shell.
HP and IP section extraction line ports. These ports should be protected by installing foam
FME plugs with tell-tale ropes and ID tags extended outside the outer cylinder HJs and tied
off to permanent fixtures.
Cross-over exhaust ports on the IP turbine outer cylinders when the IP turbine section will
not be disassembled or when the disassembly of the IP section will be significantly delayed
after the removal of the cross-over. Since these ports are located on the upper-half outer
cylinders, short (1218" or 30.546 cm) tell-tale ropes and ID tags can be used
LP turbine outer cylinders, following the removal of the upper-half outer covers. These
cylinders are normally covered by wooden dance floors to protect the exposed condenser
tubes and to provide access to the LP inner cylinders. LP dance floors do not require tell-
tale ropes and ID tags.
LP cross-under inlets, following the removal of the upper-half inner cylinders and DFLP
rotors. These ports are large bore and require plywood covers. Tell-tale ropes and ID tags
should be extended above the inner cylinder HJ and tied off to extension studs.
LP inner cylinder extraction ports, following the removal of the upper-half inner cylinders
and in those situations when the lower-half LP inner cylinders are not removed. These ports
should be protected by plywood covers, cut to match the irregular shapes of the HJ openings.
These covers do not require tell-tale ropes and ID tags.
LP inner cylinder extraction ports, following the removal of the lower-half inner cylinders.
These ports should be protected by installing foam FME plugs with tell-tale ropes and ID
tags extended outside the outer cylinder HJ and tied off to permanent fixtures.
Bearing pedestal drain ports.
Bearing oil supply ports located in the bearing shell support brackets.
Main oil pump (MOP) suction and discharge ports.
Thrust bearing oil supply ports.
Turning gear oil supply ports.
Coupling guard cooling oil supply ports.
Control block and control components.

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An example
2
of how one utility assigned responsibilities among key personnel within their FME
program to minimize the risk of intrusion of foreign material into the turbine-generator when
using FME plugs and other devices is shown in the list that follows:
The assigned turbine engineer should identify the locations for FME plug installation and
should include the installation of FME plugs within the turbine component work plans and
also the daily shift work lists.
Component work plans should be included within the maintenance work order and available
for review by both the turbine foreman and the assigned craft labor.
Daily shift work lists should be given to the turbine foreman by the turbine engineer and
reviewed during pre-shift planning meetings between the engineer and foreman.
The assigned turbine foreman should provide specific job assignments to the craft labor,
including the installation of FME plugs, and should specifically discuss the necessity for
FME plug installation with maintenance personnel during pre-job conferences.
The assigned maintenance personnel should install the defined FME plugs and should also
advise the foreman and/or turbine engineer of ports and openings that are present but have
not been identified within the work plan.
The assigned maintenance personnel should advise the turbine engineer of the location and
tag identification of FME plugs that they have installed. The turbine engineer should
maintain the FME log.
Removal of the FME plugs should also be described in the daily shift work lists (written by
the turbine engineers) and described within the component work plans.
In the event that an FME plug has been installed, but has not been identified as a removal
item on the daily shift work list, and may be covered by an imminent re-assembly,
maintenance personnel should advise the foreman and/or turbine engineer.
Turbine component assembly should be stopped until the condition is communicated and
corrected.
The turbine engineer should maintain the FME log, document the installation and removal of
FME devices in the engineers outage log, and perform an inventory audit of the FME plugs
throughout the turbine outage. In the event that an inventory audit indicates that an FME plug
may have been left in a turbine component, the log should provide sufficient information to
locate the missing plug.
Pre-outage planning should include preparation of the FME storage cage and procurement of
FME devices, tell-tale rope, and ID tags.

2

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2.11.6 Retrieval of Foreign Objects
Appendix D.7 of this report provides general guidance for recovering after loss of FMEA
control, including the initiation of a condition report, the recovery plan, and the actual retrieval
of the foreign materials. The following guidance should be considered for retrieval of foreign
objects in or around the turbine-generators.
Foreign objects dropped into turbine-generator areas come in various shapes, sizes, materials,
and weights, and each can pose unique extraction problems. Two methods of extraction are used:
Disassembly and retrieval of the dropped items
Remote acquisition and retrieval
Remote closed circuit television (CCTV), borescopes, and fiber optic scopes provide methods to
locate the dropped item; however, the difficulty is not location, but extraction. Many NDE
vendors have taken technology that was developed for inspection and adapted it for retrieval.
The ideal extraction device contains both elements: viewing (that is, location) and extraction.
Extraction methods have included everything from chewing gum (something sticky) on the
end of a rod or bar to snares, hooks, and even pigs (cloth, foam, or some material that fills the
area) pulled through the section. Magnets have been strapped to robotic video cameras to extract
small metallic/magnetic items. Pneumatically operated jaws/fingers/grippers/extractors have also
been used to extract odd-shaped or non-magnetic items. The most difficult item to extract is
something large, heavy, and non-magnetic, especially if geometrically difficult terrain must be
negotiated. A large vacuum can be used to extract small debris found in lines. A limitation for
vacuuming is the diameter of the line to be cleaned.
Most likely, the extraction of dropped parts will be required during reassembly, delaying critical
path activities.
2.11.7 Video Inspection of Shells and Steam Lines
Appendix D.8 of this report provides additional programmatic guidance on the close out of
FMEAs. The following guidance should be considered for closing out an FMEA that includes
the turbine-generator.
Before closing a turbine section, it is a good idea to inspect between the shells to verify that no
foreign material is located there. Inspection between shells can easily be done with borescopes,
fiberscopes, or video cameras. Internal pipe inspection can be a bit more challenging than
between shells. Remote robotic cameras are the preferred method of internal pipe inspection. The
robot must be able to navigate vertical sections of piping with the ability to articulate the camera
views. Planning for the outage includes identifying internal pipe dimensions to be inspected and
the total length to be traversed.

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2.12 Training
Preparing the personnel to perform an outage is just as important as developing the plan or
creating the schedule. The training should be customized to accommodate the type of
maintenance personnel performing the outage. If the support staff is part of a centralized
maintenance organization and dedicated to performing outages throughout the utility, the pre-
outage training will be focused on the specific activities to be performed and may involve a
different cross section of personnel than a decentralized maintenance organization.
Decentralized maintenance management can be defined as outage support provided only by the
plant. The training for a decentralized maintenance staff maintains a different focus that that of a
centralized maintenance staff. Because a decentralized maintenance staff is not focused year
round on turbine outages, the training will include more basic, generic, and refresher
information. The information presented here focuses on a decentralized maintenance concept.
The information can easily be adapted to centralized maintenance focus by extracting only the
unit-specific information.
The purpose of training is to enable plant personnel to identify, inspect, and maintain the turbine-
generator unit with the knowledge that will allow them to approach the maintenance activities
with confidence. Participants will accomplish this by gaining an understanding of machine
operation, maintenance practices, safety, damage mechanisms, and the work planned for the
turbine-generator.
2.12.1 Training Formats
Training can be conducted in a variety of formats and durations. The ideal timing is a one week
course held two weeks before the outage; the following week would be dedicated to pre-outage
activities.
Computer-based training (CBT) can be used for some of the general maintenance practices and
can be accomplished before formal training begins . Student-instructor participation and
interaction is the recommended format, especially for detailed specific maintenance practices and
specific work scope presentation. Attendee selection may vary based on utility guidelines, but
should at least include all turbine-generator supervisors, and technical support personnel. It can
include support contractors and even vendors at the appropriate time. The ideal setting includes
all personnel who will be performing the turbine-generator maintenance.
Instructors should be personnel involved with the outage. Journeymen or maintenance
supervisors may present specific maintenance activities, for example, field or turbine rotor
removal. Technical direction personnel may review the readings to be taken and the reasons for
taking them. The planning department should be represented to review and discuss the outage
plan and schedule. Vendors may be asked to present a demonstration on use and repair of their
tooling. A repair vendor may be asked to present damage mechanisms, assessment, and repair
processes. The training must be focused and profitable to the attendees to be effective.

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Training can be organized into a single general session where all attendees receive the same
information. It can also be organized as a general session where the outage plans are presented
and specialized sessions where the unique section information is presented.
2.12.2 Recommended Training Topics
The following is a breakdown of the topics that should be considered in turbine-generator pre-
outage training. A detailed list of subjects is presented in Table 2-23.
1. Turbine-generator basics
The items listed for this and for each topic are comprehensive, but the items listed can be
grouped and tailored to meet the specific need of the attendees. Outage staff with very
limited exposure or staff that does turbine outages only once a year can benefit from the
comprehensive list. The minimum exposure during training is the preparation for the work to
be accomplished and included under the planning section.
2. Maintenance Practices
A listing follows of the various topics for which the utilitys maintenance practices would be
presented. Included within the description are standard practices performed and special
methods or standards that were developed by the utility. Examples would include the use of
hydraulic wrenches instead of sledgehammers. Included in the training would be pictures,
graphic displays, and written instructions on how to perform the listed operation. The idea is
to be unit- or utility-specific, not generic.
3. Inspection testing and repair
The purpose of this training is to provide the attendee with background information regarding
why damage occurs, what damage to look for, and what repairs are required. The attendee
will also be provided with generic cleaning, NDE, testing, repair information, and specific
repair information when applicable.
4. Planning
The planning portion provides all the information that has gone into the making of the
upcoming outage. Everything unique to that outage is presented. The first sections focused
on the machine itself, with unchanging or slow-to-change practices. This section focuses on
what is going to be done during this outage and may be limited only to this outage.

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Table 2-23
List of Recommended Training Topics
Turbine Generator Basics
Turbine construction Flow path, sections, extractions, components
Generator construction Stator, methods of cooling, field
Section and
component
terminology
Orientation: Left and right. TE, GE and CE. Upper and lower
Numbering: Odd and even. A,B, and C.
Identification Hood, casing, shell, packing casing, packing head, diaphragms, rotors,
valves, generator, exciter
Operation Turbine, generator, stress, thermal growth, auxiliaries
Maintenance Practices
Documentation Entry requirements, forms, process instruction sheets, vendor/turbine
deck repair sheets, discrepancy report, drop list
Rigging Rigging manual, how to flip, hand signals, rotors, field, valves
Tools Tool room, how to use, tips on repeatability of readings, hydraulic
wrenches: proper use, dos and donts, maintenance, applications
Sequence
Disassembly and
reassembly
Thermal lagging, crossover piping, horizontal joint bolting, joint feeler
checks, rotor position checks, coupling checks, bearings: [journal, thrust],
bearing checks: [support pad blue checks, blue checks and scraping,
mandrel checks, measuring journal and bearing, tilt and twist, pinch
checks, hydraulic coupling bolts], component removal: [shells, casings,
hoods, rotors, diaphragms upper and lower, packing cases], valves:
[stop, control, intercept, reheat stop, ventilator, non-return], generator:
field removal
Alignment Internal: [philosophy, required reading position clearance checks, rotor
clearances], interpretation: [refined readings, determining need for
alignment], diaphragm realignment: [radial crush pins, arch spring
supports, centering pin], external: [required readings rim and face],
Interpretation: [refined readings, determining need for alignment, coupling
alignment: [calculated bearing moves, changing shims]
Auxiliaries Lube oil, seal oil, EHC system, stator cooling water system, extractions,
iso-phase cooling, steam seals.
Inspection and Repair
Cleaning methods Grit blast, stoning, strap lapping, wire brush, chemical
NDE methods Visual, PT, MT, UT, eddy current, RT, hardness, etching
Steam path inspection Diaphragms, buckets, sealing areas
Type of distress Erosion: [solid particle, water, steam cutting], deposits, Cracking:
[chemical, mechanical], Chemical attack: [corrosion, pitting], Electrolysis,
FOD, distortion

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Table 2-23 (cont.)
List of Recommended Training Topics
Inspection and Repair (cont.)
Rotor and field Couplings, journals, wheels, packing areas, buckets: [vendor repairs],
shrouding/covers, rotor bowing [reasons], stress, size/construction,
operation, detection [in-service, during outage], slow speed balancing
[imbalance, resolution], end plane, midspan [cleaning in service balance
locations]
Stationary components Casings, joints, packing, nozzles, diaphragms [spill strip removal, packing
removal, ledge and seal key, vendor repairs], bearings, bolts
Bearings Wear patterns, bonding and cracking, clearances, contact checks, repairs
[onsite, scrapping, off-site]
Valves Body, pressure seal area, stem, disc, bolting, crossheads, strainers,
actuators and linkage
Repair/replace/reuse
decision process

Planning
Planning Disassembly focus, major jobs, work orders, outage schedule, sandblast
schedule, NDE schedule, pre-shutdown activities, pre-shutdown
maintenance, lay down plan, environmental MSDS/hazardous waste
disposal, vendors
2.12.3 Training Options
Many of the training vendors provide turbine-generator training that can be customized to a
specific type of turbine-generator. This is an alternative to creating in-house training for:
Turbine-generator basics
Maintenance practices
Inspection and repair
2.13 Rigging, Special Tools, Parts, and Expendable Materials
Pre-outage planning includes a review of availability and status of rigging and special tools. An
inspection program of lifting devices prior to the outage is prudent; this includes crane hooks,
lifting cables, eyebolts, and lifting beams. The inspection program should serve two functions:
the first is NDE and the second is an inventory of available lifting devices. It is not uncommon to
have cables or lifting devices borrowed during non-outage periods and returned damaged or not
returned at all.
Special tools such as hydraulic wrenches, hydraulic power packs, porta-powers, and tooling that
supports work centers should be functionally inspected and repaired if necessary prior to the
outage. Although tools should be repaired after an outage and before storage, there is always a
seal or a hydraulic fitting that leaks or a pump that will no longer pressurize. Special tooling to
support rotor-turning devices such as slides, tool posts, oilers, misters, etc., should be inspected
for correct operation.

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The last outage report should be reviewed for specific comments regarding lifting device
modification and component stands. The use of safety netting around the turbine pedestal to
prevent components from falling on anyone or anything below should be reviewed. The
manufacturer recommendations should be reviewed for inspection requirements, testing, etc. The
pre-outage review should also focus on the use on consumable or expendable materials. A
comprehensive list should be kept each outage and reviewed before the next outage. Table 2-24
lists typical consumables used during an outage.
Table 2-24
Typical Consumables Required for an Outage
Category Item
Typical adhesives and
sealants used by some
utilities
3M Super 77 spray, Belzona super meta,. Fluorosilicon (fittings,
sealant), GE R V 60 without catalyst, Superglue, Ultrablue
Permatex RTV
Cleaning Brushes (metal scratch (tooth brush), paint, tube cleaning), cleaning
compounds (degreaser, denatured alcohol, detergent (parts
washer), hand cleaner (5 lb can) (2.27 kg), solvent, water-soluble
soap), cleanup (broom, broom handle, dust pan, floor squeegee),
oil absorbent (sock, loose), spray bottle, towels (paper), rags (lint
free, regular), trash can liner (large, small)
Gases and coolants Argon, dry ice, nitrogen, oxygen
Inspection Fuse wire 0.025" (0.635 mm), 0.028" (0.711 mm), 0.031"(0.787
mm), feeler gauge, information tags, leak detector snoop,
markers (felt, metal, soapstone), Prussian blue, shop ticket holders
Lubricants Fasteners (anti-seize, penetrating, thread lubricants), lube oil
strainer bags, oil (triple-boiled linseed, gear, hydraulic, jack, multi-
purpose, synthetic), wax (paraffin, toilet seal)
Metal working Abrasives (Arkansas stone: hard and soft, grinding wheels, Scotch-
Brite: green and red), emery (crocus cloth of various grits and
widths, disc), file handles, fluids (cutting, tapping)
Personal and Protection Batteries, disposable gloves, drinking cups, ear protector, eyeglass
cleaner, industrial flashlight, lamps (incandescent, quartz lite 300-
watt), respirator (disposable, face shield)
Storage Buckets - white 5-gallon (18.93 liter), oak cribbing, pails (buckets -
white 5-gallon [18.93 liter], economy), pallets, plastic bags (large,
self-locking), plywood sheets
Gasket and Insulating Gasket material, Kaowool, non-asbestos gasket material, Rubatex
Fasteners and Lifting Hose clamps, manila rope, rope (nylon, poly-dacron, polyester),
safety tie wire, tape, cable ties
Miscellaneous Music (piano) wire 0.016" (0.406 mm), fish paper, shim stock,
tongue depressors, welding cloth

3-1
3
UNIT SHUTDOWN
During unit shutdown, practices and techniques are continuously sought to reduce the margin of
conservatism in generic loading and starting curves without damaging the thermally stressed
components of the high-pressure turbine. In addition, practical methods are also sought to
minimize the valuable critical path time that is used while waiting for the unit to cool, at which
point disassembly can begin.
This section of the guidelines identifies, reviews, and compiles the practices and techniques that
are normally involved or should be undertaken during the shutdown of a turbine-generator for a
maintenance outage, leading up to the point where the unit is brought off turning gear and
general disassembly can begin. The information here is primarily designed to identify and
describe the methods or approaches that have been used to reduce the time required to bring a
unit from full speed to placing it on turning gear. Methods or practices that have been used to
further accelerate the cooling process during the shutdown process are also reviewed. Activities
that can be undertaken while the unit is cooling, that is, on turning gear, in preparation for the
disassembly of the unit are also discussed.
3.1 Pre-Outage Testing
A number of non-intrusive tests should be performed throughout the operation cycle of the
turbine-generator and before shutting the unit down for a maintenance outage. The results from
pre-outage and post-outage test comparisons can provide insight into the effectiveness of the
outage as well as warn of potential maintenance problems.
Periodic enthalpy drop tests during the operation of the turbine can provide information that
reflects potential deterioration to the high-pressure (HP) and intermediate- or reheat- pressure (IP
or RH) turbines. Tests should be performed both before and after the outage as a way to evaluate
the effectiveness of the steam path and sealing repairs. Enthalpy drop efficiency tests are highly
cost-effective tests and can be fairly accurate, 0.25% if ASME PTC 6 type instrumentation is
used [9, p. 265]. But consistent use of station instrumentation can provide meaningful test results
if done at frequent intervals.
The unit must be maintained at a constant load before performing an enthalpy drop test. The section
inlet and outlet pressures and temperatures should be recorded while the unit is at steady load. The
load preference is valves wide-open. Valves wide-open operation reduces the pressure drop across
the valves, which is included in the section efficiency calculation. If the valves wide-open condition
cannot be consistently maintained, use a consistent valve position for the periodic test as a minimum.

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3-2
The section efficiency is calculated from the following:
Inlet condition entropy and enthalpy are determined from the inlet pressure and temperature
Outlet condition is determined from the inlet pressure and temperature.
Outlet condition isentropic enthalpy is determined from inlet entropy and outlet pressure.
These values are combined as follows to determine section efficiency:
100% x (Inlet enthalpy - Outlet enthalpy)/(Inlet enthalpy - Isentropic outlet enthalpy)
Figure 3-1 is a plot of HP section efficiency over an approximate 14-year period with three
outages. Tests were completed using station instrumentation, unit at steady load, and valves at a
reasonably constant position. The initial dip in the third operating period was caused by bad (out
of calibration) instrumentation. Notice the reset of section efficiency after each outage as well as
the steadily increasing efficiency. Also note the last operating period when steam path changes
were made. The resulting tests indicate that the new steam path components were less
susceptible to solid-particle erosion (SPE) than their predecessors.

Figure 3-1
Section Efficiency Change During the Course of Three Outages
Another non-intrusive test to assess machine condition (such as tightness in the low-pressure
[LP] section) is helium leak testing. Helium is sprayed around the LP expansion joints and areas
that are subject to vacuum operation. A probe is placed in the air ejector discharge that can sense
traces of helium.
This test is used to assist in determining the tightness of or damage to the following items:
Crossover pipe bellows
Condenser seal bellows
Extraction bellows external to the condenser

Unit Shutdown
3-3
A turbine supervisory instrumentation (TSI) system fitted with proximity probes provides real-
time shaft and bearing information during operation. This non-intrusive tool is a health monitor
during operation and a post-outage tell-tale sign of potential reassembly problems. Before the
outage, the TSI system provides vital information regarding possible bearing repairs that may be
required. This information would allow pre-outage planning for the potential repairs.
A history of machine vibration information, obtained with shaft rider vibration or proximity
probes, is also another tool that can provide pre-outage planning and machine condition
information. Rotors that are susceptible to bowing and that have received midspan balance
corrections over the operating period may be a warning of an increasing bow and a need for
subsequent action.
Flux probes installed in the generator air gap (the space between the rotating field and the stator)
may be used to predict the condition of field end turns and, therefore, are a useful condition
assessment and pre-outage planning tool. Coil distortion, abrasion, and foreign object damage
can cause shorts in the ends of the coils. A shorted turn reduces the number of active turns in the
field. The remaining coils must then carry more current to maintain the same flux density
(magnetism) in order to produce the same generator output. Generator operation may not be
significantly affected by the sorted turns. The impact on operation is dependent on location,
magnitude, and the number of shorts.
Rotor imbalance may occur when a turn is shorted and manifesting itself as a thermally (load)
sensitive rotor. This condition may first be noticed as vibration changes. Air-gap flux probes can
be used to aid in identifying this condition by detecting the flux distribution between each of the
field coil slots. This test is done at speed with load.
By implementing a comprehensive predictive maintenance program, a utility can reduce costly
equipment outages. A fundamental component of this is infrared thermography (IR). It uses non-
intrusive techniques to monitor the operating condition of equipment and components. The
EPRI Infrared Thermography Guide, 1006534, [10] provides a great deal of helpful information
on this technology. Key topics discussed are the science of thermography, selecting the correct
instruments, inspection techniques, applications, and training.
For a broader view on troubleshooting, the EPRI report System and Equipment Troubleshooting
Guideline, 1003093, [11] is available. It has a structured approach that will be helpful to any
plant personnel engaged in the troubleshooting of plant systems and equipment. In the chaotic
environment when a problem occurs and in the rush to return the system or component to
service, the true root cause of the problem may be overlooked. This report provides guidance to
help decrease the time needed to identify and restore the system to operating condition. It also
will increase the probability that the complete cause will be found and that the actual
maintenance required will be done.
3.2 Generic Steps for Shutdown
Table 3-1 presents a sequence of steps that are typically involved when shutting down a unit in
preparation for a maintenance outage.

Unit Shutdown
3-4
Table 3-1
Steps Typically Involved with the Shutdown of a Turbine-Generator
Step Activity
1 Reduce superheat temperatures, make appropriate control adjustments to reduce heat
input to the turbine.
2 Perform a slow load reduction.
3 Isolate the hydrogen system (appropriate spool pieces removed).
4 Purge the generator.
5 Isolate the seal oil system.
6 Drain the EHC reservoir.
7 Drain the stator cooling water system and prepare clearances.

3.3 Critical Engineering Concerns
The most important concern in the turbine shutdown process is to control the thermal stresses in
the rotors and casings. Keeping the steam temperature and the turbine metal temperature within
design limits controls the thermal stresses. The temperature mismatch design limits vary from
machine to machine as a result of varying geometries of the components. Large diameter rotors
have higher thermal stresses than smaller diameter rotors with identical temperature ramp rates.
The same is true for shells. The greater the shell thickness, the larger the thermal stress for
identical temperature ramp rates. Although the results of excessive thermal stresses might not be
immediate, repeated cycling of high thermal stresses can eventually cause cracking. The thermal
stresses are highest on the surface because of the stress that is caused as a difference between the
average metal temperature and the surface temperature. Cracking occurs when thermal stress
exceeds the yield strength of the material.
During the shutdown process, the surface stress becomes tensile, and cumulative cycling of this
tensile stress can cause the metal to tear. At temperatures above the rated temperature, the
materials yield strength drops considerably. This causes the risk of cracking to increase.
Because there may be no external symptoms of high thermal stresses, it is important to follow
the design temperature ramp rates while shutting the turbine down.
One problem that can lead to high thermal stress during the shutdown process is water induction.
This usually occurs in the high-temperature sections of the turbine and can be caused by reheat
attemperator valves failing to close, feedwater heaters backing up, and water in shell drains
backing up. Water detection thermocouples are installed in many turbines and should be
monitored during the shutdown process to identify the presence of water in the turbine.
Another concern during the shutdown process is the accumulation of chemical deposits in LP
turbine blades. The moist steam in the LP turbines contains chemicals that may be harmful to the
blade attachment and dampening areas. It is important to reduce the amount of moisture in the

Unit Shutdown
3-5
LP turbine during the shutdown process to reduce the amount of chemicals that are deposited in
the critical blade areas. These chemicals corrode the metal and can change the frequencies at
which the blades vibrate. A change in the blade vibration frequency can lead to a blade failure
caused by high-cycle fatigue.
3.4 Parameters to Monitor
The parameters used to monitor the turbine shutdown process are:
Superheated steam temperature and pressures
Turbine metal temperatures
Differential expansion
Vibration amplitudes
Feedwater heater levels
Lube oil temperature
Bearing metal temperatures
Automatic oil pump starting
Steam turbine drains
Condenser vacuum
Gland seal steam
Turning gear operation
It is important to ensure that the generator is purged of hydrogen prior to access or performing
generator maintenance. Begin the generator purge after the turbine-generator is on turning gear.
Isolate the hydrogen system when the purge process has begun. This should include verifying
that the hydrogen system is physically prevented from leaking back into the generator by
removing a section of pipe (spool piece) between the isolation station and the generator. The seal
oil system should be isolated after the generator is purged and depressurized. The generator may
fill with oil if the seal oil system is left in operation with the stator depressurized. These activities
are completed prior to release of the generator for disassembly.
Monitoring the superheated steam temperature and pressure is necessary to keep the thermal
stresses in the rotor and casings within acceptable limits. The steam and metal temperature
differentials must be maintained according to the manufacturers acceptable limits. The best way
to maintain these temperatures is by using a turbine stress monitor. Stress monitors allow the
operator to operate the turbine at the optimum stress level. Operating at optimum levels reduces
the possibility of metal fatigue and saves money during starting and loading by ramping metal
temperatures at optimum rates.
The turbine differential expansion is a measure of the rotor relative to the turbine casing. The
expansion of the rotor is much faster than the casing; therefore, it is possible for the rotor to

Unit Shutdown
3-6
contact the casing if the differential expansion is too great. Differential expansion is not a
problem if the thermal ramp rates are kept within prescribed limits.
The turbine rotor vibration amplitudes and phase angles must be monitored during operation and
shutdown of the unit. Maintenance costs are reduced when rotor vibration levels are kept at low
levels. Some causes of high vibration amplitudes are:
Unbalance
Failure of a rotating component
Rubbing
Oil whipping
Misalignment
Thermal sensitivity
During the turbine coast-down, the vibration amplitudes will increase as the speed of the rotor
train passes through critical speeds. It is important to note the vibration amplitudes as the rotors
go through these speeds. Turbine vibration amplitude limits are set by the manufacturers and
should be kept within these limits.
The water level changes in the feedwater heater during the shutdown process and must be
monitored to keep water in the heaters from backing up into the turbine casings. Water backing
up into the turbine casings can cause high thermal stresses, which distort the casings and can
cause severe rubbing. If the water level gets high enough, it can come in contact with the rotating
blades that can cause the blades to break. The unbalance resulting from blades breaking can
result in catastrophic damage to the turbine. Some turbines have thermocouples in the casings,
located in the top and bottom of the casings, to monitor casing differential temperatures. A
temperature differential of over 50F (10C) may be a result of water entering the lower half of
the turbine casing.
The lube oil temperature should be reduced as the turbine speed is reduced. The lube oil
temperature should be between 8090F (26.632.2C) when the unit is put on turning gear. The
lube oil will not have the proper viscosity to support the rotors if the temperature is too high.
The bearing metal temperature should be monitored during coast-down to detect wiped bearings.
Bearings that are wiped cannot sustain the hydrodynamic oil film at low speeds. A sudden rise in
bearing metal temperature will result during coast-down if a bearing is severely wiped. The
adjacent bearings may also have a rise in metal temperature if they are overloaded because of a
wiped bearing.
The motor-driven oil pumps should be checked during shutdown of the turbine. These pumps
should automatically start when the oil pressure falls below a set pressure. The pressure at which
the oil pumps automatically start should be recorded and compared to the manufacturers
recommended limits. Some of the automatic oil pumps are the turning gear (ac) oil pump and the
emergency bearing (dc) oil pump.

Unit Shutdown
3-7
The steam drains should be opened during the shutdown process to keep water from entering the
turbine. The turbine manufacturers have operating procedures that give the proper sequence of
opening drains during the turbine shutdown process.
The condenser should be kept under vacuum as long as possible during the turbine shutdown. By
keeping the condenser under vacuum, the amount of chemical deposits plating out in the LP
turbine will be reduced. If used, the LP hood sprays should be turned off as soon as possible to
reduce the amount of moisture in the LP turbine. When the vacuum is broken, the gland seal
steam should be turned off. If left on, the gland seal steam could also allow moisture into the LP
turbine blading.
As soon as the unit has reached zero speed, the turning gear motor should be started and the
turning gear should be engaged. Hot turbines must be left on turning gear until the turbine is
thoroughly cooled to keep from damaging internal components. Each manufacturer has
prescribed limits for turning gear operation.
3.5 Opportunities to Reduce Shutdown Time
One opportunity to reduce shutdown time is clearing equipment as soon as possible. This may
mean issuing short clearances. A short clearance is defined as shutting down and isolating one
system so that maintenance can be performed on another system. An example of a short
clearance is the EHC system being cleared so that turbine maintenance can begin without the
possibility of the turbine re-accelerating from turning gear:
A short clearance of the EHC system occurs when the following are completed:
The EHC pump motors are racked out.
The EHC fluid supply to valves is isolated.
The EHC pump discharge valves are locked in a closed position.
The EHC fluid recirculation or bypass valve is open, preventing fluid flow to turbine valves.
A short clearance is followed with a full system clearance when maintenance can be performed
on that system.
Another opportunity to reduce shutdown time is through accelerated cooling of the turbine
through both internal and external processes.
3.6 Practices That Have Been Used to Reduce Shutdown Time
The main tool used to shorten shutdown time is the turbine stress monitor. The stress monitor is
used to determine the fastest shutdown possible, staying within the stress limits of the turbine
casings and rotors. The stress monitor uses finite element analysis to determine the highest
stressed component of the turbine and keeps the stresses at that location within their allowable
limit. Stress monitoring is done by controlling the thermal ramp rates of the turbine during
operation.

Unit Shutdown
3-8
If there is no turbine stress monitor installed on the turbine, the manufacturers operating
instructions must be used to shut the turbine down. These instructions give limits for reducing
load when bringing the turbine off-line. Many of the manufacturers instructions are
conservative, as a result of the time during which they were written. Until the 1980s, the turbine
manufacturers were not using finite element analysis routinely to design turbine components.
This means that there can be areas where the actual stresses referred to by operating instructions
are below the allowable stresses for the turbine.
When bringing the turbine down for a planned maintenance inspection, the critical time is from
full speed no load until the unit can be taken off turning gear. This period is usually about 48
hours as a consequence of the large mass of metal involved and the amount of insulation on the
turbine casings. The length of time to cool the turbine until taking the unit off turning gear can be
reduced by cooling the turbine rotors and casings while shedding load from the turbine. If the
turbine is brought off-line while the casing temperatures are high, it will take much longer to get
to the point where the unit can be taken off gear than if the casings were cooler coming off-line.
This cooling period can be reduced substantially by reducing the temperature and pressure of the
steam during the shutdown process. Cooling of the casings is performed by opening the high-
pressure steam control valves to wide open, lowering the main and reheat steam temperature and
pressure, and letting the load decay. When the desired temperature is reached, the remaining load
can be removed by closing the steam control valves. It is important to note the amount of
superheat in the steam to keep water out of the turbine casings. The turbine manufacturers give
allowable limits for steam temperature and pressure for shutting the turbine down.
Some operations that can reduce the turbine casing temperature after the unit has been placed on
turning gear are:
Remove control valves from valve chests.
Remove video inspection port covers.
Remove reheat turbine crossover pipes.
Remove reheat turbine crossover pipes.
Open shell drains
Ventilate the casings at these locations using forced air
Air cooling of the turbine casings can reduce the turbine cooling period, but it must be monitored
to ensure that the turbine metal temperature ramp rates are not exceeded. Areas to monitor while
air cooling the turbine are:
Casing temperature
Casing expansion
Differential expansion
Eccentricity

Unit Shutdown
3-9
Steam turbine manufacturers often include cooling curves that give the rate of cooling for the
high-pressure section under normal operating conditions. These cooling curves should be used to
determine the amount of time needed to cool the casings after the unit is tripped. The curves are
generally found in the operations section of the turbine instruction manual.
3.6.1 Overspeed Trip Testing
The turbine overspeed trip test is necessary to ensure that the turbine will not reach a speed that
will damage the turbine or generator in the event that the load is lost while the steam admission
valves are open. The overspeed trip test allows the turbine to reach speeds up to 112% of rated
speed on some units. Rotor speeds above 100% of rated speed create high stress and can result in
damage to the rotating components during overspeed trip testing. The main requirement for an
overspeed trip test is that the rotor bore temperature is above the fracture appearance transition
temperature (FATT). Damage can occur if high stresses are imposed to rotors below the FATT.
Before a turbine overspeed trip test can be performed, all bore locations on the high temperature
rotors must be at least 450F (232.2C). The cold end of the high temperature reheat rotors is the
exhaust end where the steam enters the crossover; therefore, the crossover temperature must be
at least 450F (232.2C) before overspeed trip testing the turbine.
The overspeed trip test should be performed during shutdown while the rotor bore temperatures
are still high. This is done at full speed with no load on the turbine. After the testing is complete,
the unit can be brought down for maintenance.
If the overspeed trip test is performed on a cold turbine, 25% load must be carried for a
minimum of four hours to warm the high-temperature rotor bores to allow overspeed tests be
performed.
One way to reduce the outage duration is to perform the overspeed trip test while the unit is
down for maintenance. This test can be performed by removing the shaft extension where the
overspeed trip is located and having the overspeed trip set under simulated conditions. This
requires that the shaft extension be spun up on a special lathe and have the trip speed recorded.
This requires the shaft extension to be at the design operating temperature in an oil bath. The
simulated overspeed trip test will keep the entire turbine train from undergoing the high stresses
involved by performing an actual overspeed trip test, as well as saving time during a shutdown of
the turbine.
3.6.2 Electrical Trips vs. Mechanical Trips
Electrical control systems have three or more speed pickups located in the front pedestal that
measure the speed of the turbine rotor. By controlling the speed with electronic speed pickups,
the electrical control systems do not require mechanical devices and are, therefore, more reliable
and easier to maintain. The electrical control system can measure acceleration as well as speed,
and electrical controls are used for overspeed protection of the turbine.

Unit Shutdown
3-10
Mechanical control systems on older steam turbines can be upgraded to electrical control
systems, and the controls can be more reliable. Electrical control systems can control speed, load,
and overspeed much more accurately than mechanical control systems. Mechanical control
systems have governors, speed relays, pre-emergency governors, gear drives, cup valves,
bellows, and pilot valves. These components, with their connecting levers and linkages, require
extensive maintenance. Electrical control systems have fewer moving parts and, consequently,
require less maintenance. It is easier to simulate an overspeed trip with an electrical control
system, which makes periodic overspeed testing of turbines much easier. Valve tests are also
easier to perform with electrical control systems.
Although electrical control systems are better than mechanical control systems, they are
expensive to retrofit onto older turbines. The addition of electrical controls to older turbines is
often justified by more accurate speed/load control, lower maintenance costs, ease of testing, and
better reliability.
3.6.3 Boiler/Reactor Feed Pump Turbine Controls
The feedwater systems in many nuclear plants use steam turbine-driven feedwater pumps, which
are necessary to supply a large flow of feedwater at the required pressure with high reliability.
This type of pump driver in the feedwater cycle effectively uses the plant steam cycle to
economically drive a large horsepower pumping operation. To establish good maintenance on
the turbine/pump is important, considering that nuclear records have indicated that turbine-driven
feedwater pumps are a high contributor to plant derates and forced outages. These turbines use
one of three control systems: mechanical/hydraulic control (MHC), electrical/hydraulic control
(EHC), and electronic digital control (EDC).
The EPRI report Feedwater Pump Turbine Controls and Oil System Maintenance Guide,
1003094, [12] is available to provide maintenance information for the feedwater pump turbine
MHC oil systems. The guide is intended to assist nuclear power plant maintenance personnel in
troubleshooting and maintaining the MHC system. It contains a reference for understanding the
control philosophy, technical descriptions for the different elements within the control system,
and also routine and preventive maintenance guidance to improve reliability.
3.7 Removal of Covers and Crossover Piping
Install platforms on the low-pressure exhaust hoods for the removal of the crossover pipes during
the setup week prior to the outage. An example of access platforms is shown in Figure 3-2.

Unit Shutdown
3-11

Figure 3-2
Example of Access Platforms
Every other crossover flange bolt is removed as soon as the generator is taken off-line and the
short EHC clearance is in place. Unit condition is off-line with the turbine-generator on turning
gear. The remaining flange bolts are removed as soon as the condenser vacuum is broken. The
condenser vacuum is broken within three to six hours after the unit is taken off-line. Therefore,
crossover piping removal occurs 1012 hours after the unit is taken off-line.
3.8 Valve Disassembly
Scaffold erection to support valve disassembly should be completed during the pre-outage week
but may continue into the first week of the outage. Access to combined reheat valves (CRVs)
and separately mounted control valves (CVs) is the first priority, with separately mounted stop
valves (SVs) a lower priority. CRVs and CVs are removed as soon as resources are available;
typically, this will occur within the first 24 hours after the unit is removed from service but no
later than 3648 hours. Removal of the valve components provides a cooling path for the turbine
components. Valve linkage removal occurs first with scaffolding modification as a likely
subsequent activity depending on the valve arrangement and the original scaffolding installation.
Cooling air is forced into the CVs toward the HP turbine to facilitate cool-down. The CVs that
provide steam flow to the lower HP shell are the first priority for cooling airflow. Additional
airflow is provided as the CVs/main steam leads feeding the HP upper shell flanges are unbolted
and separated.
Linkage removal for separately mounted control valves is estimated at six hours per valve. The
remainder of the control valve disassembly is estimated at eight hours per valve. Completion of
valve removal is resource-dependent but is typically completed within the first week of the
outage. Separately mounted stop valves are disassembled in conjunction with the control valves.
Total disassembly time estimate is 16 hours per valve and includes lid removal, pressure seal
head removal, disassembly, etc. SVs are also resource dependent for disassembly, but
disassembly should be completed during the first weeks of the outage.

Unit Shutdown
3-12
3.9 Practices to Accelerate Cooling
The following are opportunities to remove heat input into the turbine during the shutdown
process:
Reduce superheat temperatures by approximately 100F (37.7C) approximately 12 hours
prior to shutdown begins to reduce the heat input into the turbine and lower valve and HP
turbine temperatures.
Lower the main turbine lube oil supply temperature as soon as the turbine is on turning gear.
Purge the generator as soon as the turbine is on turning gear.
Remove the HP and IP horizontal joint lagging as soon as the unit is off-line.
Install air hoses to blow air through the horizontal joint bolting of the HP and IP sections
after the horizontal joint lagging is removed.
Remove valves and insert air-moving devices to provide a cooling flow through the turbine.
3.10 Operations Performed During Turning Gear Operations
A distinction is made between maintenance activities performed while on turning gear and while
off turning gear with the lube oil system still in operation. The lube oil flowing to the bearings
provides cooling to both the bearing and the turbine rotor. Turbine-generator disassembly begins
as soon as the unit is on turning gear and the appropriate clearances are in place for maintenance
to begin. Disassembly while on turning gear is limited to non-oil wetted areas. This includes
valves, crossover piping, and joint bolting.
More maintenance and disassembly options may be exercised after the hotter HP and IP sections
of the turbine have decreased in temperature. Off turning gear disassembly can begin in the oil-
wetted areas and other areas of turbine-generator sections when certain conditions exist in the
hotter HP and IP sections.
The following is the sequence of activities to put the unit on turning gear with hot HP and IP
sections:
1. The turbine-generator is taken off turning gear when the first stage metal temperature is
reduced to approximately 500F (260C).
2. The lube oil system is left on to cool the bearing.
3. The bearing metal temperatures are monitored not to exceed 250F (121.1C).
4. The time rate of change of the bearing metal temperatures is also monitored to predict the
expected maximum bearing metal temperature.
5. The bearing metal temperatures will initially rise because rotor heat is conducted through the
rotor and rejected at the bearing.

Unit Shutdown
3-13
6. If a bearing metal temperature curve for a specific bearing begins to rise above 225F
(107.2C) and approach 250F (121.1C):
a. The unit is returned to turning gear.
b. The unit remains on turning gear while the first stage metal temperature decreases 50F
(10F).
c. The cycle is repeated until the bearing metal temperature has stabilized below 250F
(121.1C).
7. The lube oil system is momentarily removed from service to install oil supply toggle blanks,
as described in Section 3.11.
8. The lube oil system is returned to service to continue cooling the HP section and bearings.
9. The lube oil system remains in service until the first stage metal temperature is lowered to
approximately 400F (204.4C).
10. The lube oil system is then removed from service, and the bearing metal temperatures are
monitored as noted above.
Figure 3-3 is a plot of shutdown activities showing main steam temperature, generation, first
shell metal temperature, turbine speed, and one of the HP bearing metal temperatures. The
turbine was taken off turning gear after approximately 15 hours after the unit was taken off line.
The first stage metal temperature was approximately 520F (271.1C).

Unit Shutdown
3-14

Figure 3-3
Plot of Shutdown Activities
Cooling rates and the effect on the bearing metal temperatures will vary, depending on the
amount of cooling acceleration methods used. Figure 3-4 plots two different occasions that were
monitored during cool-down when the entire unit was not to be disassembled. The case
represented by the dotted line used accelerated cooling techniques, but the case represented by
the solid line did not. The blips on the solid line (at 10+ hours and 30+ hours) represent the
bearing metal temperature of an HP turbine bearing while lube oil was removed from service.
Lube oil blanks were installed in the generator feed line during the 10+ hour activity in order
to isolate the generator from the lube oil supply. Generator disassembly could begin after the
blanks were installed. Lube oil was then returned to service in order to continue cooling the
turbine bearings.

Unit Shutdown
3-15
The lube oil was off for approximately two hours while the blanks were being installed. It is
interesting to note that after the lube oil was shut off, it took approximately seven hours to fully
develop a steady-state temperature in the HP bearing that was being monitored. Lube oil was
removed from service at approximately 420F (215.6C) during the accelerated cooling
procedure so that turbine maintenance could begin approximately 30 hours after shutdown. For
the non-accelerated procedure, if lube oil was shut down at approximately 420F (215.6C) first
stage metal temperature, turbine maintenance could have begun at 48 hours into the outage. The
outage time saved between the accelerated case (see Figure 3-4) versus the non-accelerated case
is 18 hours. Both cases are well within the acceptable range.

Figure 3-4
Plot of Accelerated vs. Non-Accelerated Cool-Down Rates
3.11 Lubrication Oil Blanking
Blanking of selected oil lines can accelerate the disassembly process of the turbine-generator.
Generator disassembly can begin within 2436 hours after the unit is removed from service, that
is, after all the necessary unit clearances have been taken, selected parts have been tagged to be
left untouched, and the oil supply lines have been blanked.
An example of a toggle blank is shown in Figure 3-5. The figure on the left is a standard orifice
strainer. The orifice strainer is removed, and the device on the right is installed. The orifice
strainer threaded retainer is replaced with a threaded retainer that is drilled and tapped. An all-
thread rod is used to apply pressure to the gasketed sealing plug. A machine swivel or similar
device is used to attach the all-thread rod to the sealing plug. When the oil system is restarted,
the flow of oil to the bearing is blocked at the gasket surface of the plug.

Unit Shutdown
3-16

Figure 3-5
Example of a Toggle Blank
3.12 Removal of Insulation
Removable insulation sections are usually associated with:
Horizontal joints of the HP and IP shells
Main steam inlet flanges
Valve covers stop/control/reheat
Crossover flanges
The insulation covers are usually removed as soon as the unit is removed from service.
3.13 Lagging Removal
The turbine appearance lagging is removed during the pre-outage week. Appearance lagging
sections should be removed in pieces as large as possible. The interconnection between pieces
and assembly flanges assists in strengthening the sections during transportation. Sections should
be removed and placed in outdoor storage during the outage.

4-1
4
DISASSEMBLY AND RECORDING CLEARANCES
A significant portion of critical path time involves the unbolting and removal of turbine shells
prior to the cleaning and inspection of the turbine. When the shells have been removed, many
power plants still rely on tape measures, gauges, feelers, sliding parallels, and other manual
tooling to record turbine axial and radial clearances. This process is time consuming and is often
difficult, given the distractions on the turbine deck during the disassembly process. Managing the
massive amounts of information that need to be systematically collected and recorded can be
greatly enhanced with some type of rapid feedback mechanism, for example, correctly relating
measurements taken during disassembly to appropriate unit design measurements can prevent
problems during turbine re-assembly.
This section of the guidelines identifies, reviews, and compiles the practices and techniques that
are normally involved or should be undertaken during the disassembly phase of a turbine-
generator maintenance outage, leading up to the point where the unit is ready for cleaning and
inspection. The information contained within this guideline is primarily designed to identify and
describe alternative methods or approaches that have been used to reduce the time required in the
unbolting and removal of the turbine inner and outer shell. Methods, tools, and practices that can
accelerate the recording of clearances at the time of disassembly are then discussed. A more
detailed review of alignment procedures is found in Volume 3.
4.1 Planning Lay-Down Areas
Locations to place each component or group of components removed from the turbine-generator
are determined prior to the outage and expressed on the turbine deck lay-down plan. The lay-
down plan may not only include areas on the turbine deck but also satellite areas located away
from the deck. Turbine deck lay-down plan preparation is best organized by first identifying the
requirements for placing and servicing each component. This includes any special requirements
for each component. Therefore, it is important to evaluate and research the total impact of
component activity, whether it is by in-house personnel or vendor support. Knowing the support
and area requirements will help to prevent logistical difficulties such as those listed in the
following common examples:
The turbine deck lay-down plan identifies a footprint of the rotor. The vendor arrives
requiring at least double the rotor footprint for doing the rotor boresonic inspection.
The typical power supply is 440 volt, 60 amps, three-phase. The vendor arrives needing 220-
volt, 30-amp, single phase.

Disassembly and Recording Clearances
4-2
The turbine deck lay-down plan identifies a footprint of the component work area around the
equipment. The vendor arrives with three large storage containers (sea vans) of tools and
equipment.
Identifying with a checklist and working through a systematic approach will help to ensure the
appropriate placement of each component and access to perform inspections, repairs, etc. The
items contained on the checklist should identify all pertinent information required to help
formulate the lay-down plan. Additional descriptions and details are included in subsequent
subsections. Table 4-1 is an example checklist for preparing a lay-down plan; not all items
pertain to a specific component, and all items may not be essential during the entire outage. An
example of unique requirements is making provisions for restroom and eating locations to
support a large vendor work force that will be on-site for a limited time.
Table 4-1
Checklist for Preparing a Lay-Down Plan
Location &
Size
Lifting
Option
Utility
Requirements
Support
Component Weight
I
n
d
o
o
r
s

O
u
t
d
o
o
r

L
a
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D
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e
a

W
o
r
k

A
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e
a

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e
r
h
e
a
d

P
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c
k
e
r

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t
h
e
r
,

L
i
g
h
t
i
n
g
,

A
i
r

E
l
e
c
t
r
i
c
i
t
y

W
a
t
e
r
,

D
r
a
i
n

M
a
c
h
i
n
e

S
h
o
p

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t
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P
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r
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l

Comments
HP outer
upper shell
100,000 lb
(47,627
kg)
X X X X X X X Standard shell
maintenance plus
steam lead flange
face machining
and seal ring
replacement.
Requires
scaffolding and
work platform for
face machining.
HP rotor

LP hood
33,000 lb
(14,969
kg)
66,000 lb
(29,937
kg)
X

X
X

X
X
X

X
X

X
X X

X X
X

X

Requires two lay-
down activities,
boresonic and
bucket in work
center. Condenser
seal bellows
replacement plus
standard
maintenance.
Field 163,000 lb
(73,936
kg)
X X X X X X X X X X X X Rewind requires
retaining ring
removal, coil
handling, and
storage, work
platforms.

4-3
4.1.1 Material Handling Methods and Considerations
One important consideration in the turbine deck lay-down plan is material handling needs,
especially to ensure access to components after they have been set on the turbine deck. Some
components are set only once using the overhead crane; others are set and then must be handled
to clean, inspect, and repair. How these components are handled or manipulated must be
reflected in the lay-down plan. Material handling needs include placement of supports, racks,
cribbing, pickers, portable gantry cranes, and other equipment.
For example, the HP outer upper shell is removed from the unit and placed on the turbine deck
with the horizontal joint bolting still in place (the lower nuts are removed, the upper nuts are still
fastened to bolts). The bolts and upper nuts are later removed for cleaning and NDE. Placement
of the HP outer upper shell on the turbine deck lay-down plan should include consideration for
removal of the joint bolting. The only available resource to remove the bolts may be the
overhead crane if the shell is placed with limited access. Placing the shell in another location
may allow for faster removal with smaller portable devices.
4.1.2 Component Disassembly Requirements
Often components are removed during the turbine-generator disassembly that later require
additional disassembly. This includes such components as valves, lube oil pumps, shell
components, and generator fields. Knowing construction and work scope for a component
provides insight into the additional disassembly requirements. As mentioned, the HP outer upper
shell is removed from the turbine with the bolts still loaded. These fasteners require removal to
inspect the fastener, the shell spot faces, and the geometry around the fastener locations.
Therefore, consideration must be given when placing the HP outer upper shell to include not
only the maintenance to be performed on the shell and access to the fasteners, but also access to
and placement of the fastener racks.
4.1.3 Component Work Scopes and Work Centers
Often inspection or repair personnel are required to perform their activities wherever the
component is located. This requires transporting their equipment to that location and then
performing the activity. Lighting, contamination control, access, and other conditions may not be
the best in that setting.
For multiple components with consistent work scopes, the work center concept is used.
Components are moved in and out of a work center as the required activity is completed instead
of the personnel and their equipment being moved. The work center includes all necessary
support and access to perform the required activity. An evaluation of the activity requirements is
needed to determine whether the work center is the best solution.

4-4
Factors to consider in the evaluation of whether a work center should be considered include:
Number of times a component is handled
Support available to perform the required function
Utilities lighting/power/air/water/drains
Proximity to other activities and resources
Cleanliness
Access
The following is an example of a rotor work center that allows the following different activities
to be performed in a single setting:
Rotor runout checks
Steam path inspection
Rotor body repairs
Bucket repairs
Multiple rotors can be addressed if equipment and personnel resources are available. Figure 4-1
shows an example of a work center layout. The work center is located in close proximity to
power for all of the support equipment, to air supply for hand tools, and to sufficient lighting to
be able to perform activities; it is organized to minimize personnel travel to complete the
required activities. Work tables are sized both in strength and in surface area to perform the
required work scope.

Figure 4-1
Example of a Work Center Lay-Out Plan

4-5
Another example of a work center is the diaphragm repair area. The diaphragm repair area
should be self-sufficient. Considerations for self-sufficient workstations include the following:
Utilities lighting/air quality/power/argon/air
Work shelves for tool boxes
Welding screens between work stations
Access to diaphragms racks/stands/rigging and lifting resources
Diaphragm layout equipment
The turbine deck lay-down plan would arrange the diaphragms in proximity to the diaphragm
repair area and group them by turbine section and expected repair scopes. The diaphragms
expected to be repaired and the lighter diaphragms are placed within easy lifting range if a picker
or other portable lifting device is used. The larger and heavier LP diaphragms would be stationed
at the perimeter of the diaphragm repair area. These diaphragms are usually repaired in the
diaphragm rack. Any moving of these diaphragms is done with the overhead crane. Figure 4-2
shows an example of a turbine deck repair area with work center layouts to match expected work
scopes.

4-6

Figure 4-2
Lay-Out Plan with Work Center Layouts to Match the Expected Work Scope

4-7
For a generator, it may not be practical to ship a field for rewinding to a maintenance facility
designed for rewinds. Therefore, it becomes necessary to do the rewind on the turbine deck or in
other plant location. The real estate requirement for a field rewind is probably greater than for
any other single activity during an outage. The activities and facilities generally required to
rewind a generator field are listed in Table 4-2:
Table 4-2
Activities Required to Support a Generator Field Rewind
Item Activity Description
Clean room Rotor support retaining ring removal
Field disassembly and reassembly
One-and-one-half times the
length and three times the
width of the rotor
Sand/bead blast
area
Coil cleaning
Wedge cleaning
Coil length and width plus
work-around room
Sea vans Material and equipment storage
Work rooms
Personnel facilities

Equipment Induction heating for coil removal and baking
As a rule of thumb, adequate space utilization planning is key to the successful rewind of a
generator during an outage.
Other possible candidates for work centers are:
Bearings inspection, repair, fitting
Valves
Sealing areas
Packing interstage, shaft end
Spill strip
Oil deflectors
4.1.4 Component Weights and Floor Loading
During normal operation, the turbine-generator components are assembled on a large steel-
reinforced-concrete structure called a turbine pedestal. The pedestal looks like a large table
with multiple legs and is a separate structure from the turbine deck. One design consideration
during the construction of the pedestal is supporting the weight of all the turbine-generator
components. During an outage, these components are disassembled, removed from the pedestal,
and placed on the turbine deck and other possible locations.

4-8
Like the pedestal, the turbine deck has been designed to carry loads that may be placed on it
during an outage, but its loading capacity is probably less than the turbine pedestal. Therefore, it
is important to evaluate the turbine deck loading and structural consequences while the turbine
lay-down plan is being orchestrated and before turbine-generator components are disassembled
and placed on the turbine deck.
The plant design architectural and engineering (A/E) contractor should have supplied turbine
deck loading design information used during the original construction of the turbine deck.
Loading should be described as live loading in pounds per square foot (kg/m
2
). The turbine
engineer should compare the original conditions of the turbine deck and supporting structure to
the current turbine deck conditions to determine if any changes have been made that will impact
the live loading capability of the turbine deck.
Examples of changes to look for are:
Storage of other components on the turbine deck
Installation of other equipment on the deck or on other levels beneath or above the turbine
deck
Facility additions
Component weight and component footprint are both required to determine turbine deck loading.
Component weights are typically supplied by or available from the turbine-generator
manufacturer. If unavailable, calculation of the component volume and application of material
density should be a conservative weight estimate. Component footprint is important in the
analysis because some turbine components are large and may span structural members so that
loading is changed from concentrated to uniform. The moment implied to a given span for a
simply supported concentrated load at the center is twice the amount if that same load were
uniformly distributed; correspondingly, the beam bending stress is twice that of the concentrated
load. It is important to include all support equipment in the loading plan that will be used in and
around the turbine-generator components during the outage maintenance activities.
Figure 4-3 shows an example of a loading reference determined for the turbine deck that can be
included on the turbine deck lay-down plan. The area displayed in the figure corresponds to the
support grid of the turbine deck and the live loading that can be supported.

4-9

Figure 4-3
Example of Loading a Reference for a Turbine Deck
4.1.5 Tooling/Support Locations
Tooling and support equipment should be located as close to the outage maintenance activities as
possible. Proximity locations reduce travel time during these maintenance activities.
Consideration should be given to creating satellite support locations on or near the turbine deck
to perform such activities as machining and welding. Having a satellite machine shop on the
turbine deck reduces waiting and travel time during many of the small job activities that occur
during outage maintenance and machine assembly. The utilitys primary machine shop supports
other outage activities and may not be able to support the turbine-generator machining priority.
A satellite machine shop may be supplied by a vendor in the form of a trailer or sea van, or it
may be temporarily installed equipment on the turbine deck by the utility.
The minimum equipment associated with a satellite machine shop should be:
12" (30.48 cm) lathe
Bridgeport-style mill
Surface grinder
All the support tooling, fixtures, and perishable tooling
200 lb. (90.7 kg) capacity jib crane, if enclosed

4-10
One hundred percent staffing of the satellite location is not be required if the satellite machine
shop is utility supplied. Instead, a machinist will be required to staff the location and support the
scheduled activities. An example of required machinist support is during alignment and key
fitting of diaphragms and shells.
Table 4-3 lists examples of tooling and support that should be considered in the turbine deck lay-
down plan.
Table 4-3
Tooling and Support for Turbine Deck Lay-Down Plan
Support Tooling
Tool room Consumables, rigging (slings small chain falls, come-a-longs), gauges (dial
indicators, micrometers, precision tools), extension cords, extension lights
Rigging Cables, lifting eyes, shackles
Wrenches Racks, hydraulic, heating rods for bolting extension
Lifting beams
Machining facilities Main, portable, satellite locations
Metal fabricator Welding machines, welding supplies, welding screens
4.1.6 Power/Air/Water Requirements
The following utilities should be identified on the turbine deck lay-down plan:
Power voltage/amperage/phase/breaker locations
Air
Water
Drains
Repair equipment needs should be matched to locations of utility resources. For example, NDE
may require a 200-amp power source to mag-particle (magnetic particle) test a turbine rotor.
Placement of the rotor and/or work center in proximity to the power supply should prevent
delays during an outage if the rotor must be relocated for the inspection. The power supply may
also be brought to the rotor location and/or work center before the outage if the requirement is
identified in advance, thus reducing delays during the outage.
4.1.7 Personnel Needs (Restrooms, Eating Facilities)
Turbine decks may be constructed without adequate restroom and eating facilities that are
required to support outage work force requirements. Identification of the required work force that
will be working on the turbine deck will help to evaluate the need for additional restroom and
eating facilities. Having these in the right proximity to the turbine deck activities further reduces
personnel travel time at lunch and breaks.

4-11
4.2 Features of the Basic Rigging Plan
The rigging plan should contain the utilitys standard lifting and rigging requirements (riggers
handbook) and component-specific rigging information. The utilitys rigging manual should
contain safe loading information for lifting eyes, shackles, cables, cable arrangements, and other
rigging equipment. Component weight information should be available and should be presented
on the turbine lay-down plan. A catalog of lifting devices should be available and should contain:
Item identifier
Quantity available
Name
Description
Use
Specification as appropriate
The lifting crew, before the lift, should review each critical lift. The review should include what
is being lifted, the equipment to be used, who is controlling the lift, and where the component is
going.
The following two EPRI reports provide extensive lifting and rigging programmatic and practical
information:
Lifting, Rigging, and Small Hoist Usage Program Guide, EPRI, Palo Alto, CA: 2003,
1007914.
Riggers Handbook, EPRI, Palo Alto, CA: 2004. 1009706.
4.2.1 Rigging/Lifting Drawings for Major Components
The minimum requirements to be included on a lifting drawing are:
The weight of the component
Location of the center of gravity
Lifting points
Dimensions of the component
Figure 4-4 is an example of a lifting drawing that shows minimum lifting requirements; Figure
4-5 is an example of a detailed rigging/lifting drawing.

4-12

Figure 4-4
Example of a Lifting Drawing

4-13

Figure 4-5
Example of a Detailed Rigging and Lifting Drawing

4-14
Some components may require more details to rig and perform the lift. A comprehensive
drawing could include the following items:
Equipment identification
Rigging orientation
Rigging equipment
Loading
Lifting and clearance details
Setting location and orientation
4.2.2 Rigging Devices, Lifting Bars, Wire Rope, Synthetic Slings, and Shackles
Figure 4-6 shows examples of special rigging fixtures for performing maintenance on CRVs. In
each case, special fixtures were designed to facilitate not only the maintenance activities but also
enhanced safety and performance of rigging and lifting.

Figure 4-6
Rigging Fixtures for CRVs

4-15
Figure 4-7 shows another example of developing a fixture to assist the rigging and lifting of a
valve component in preparation for a maintenance activity. The turbine engineer should be
involved in observing existing practices and working with the maintenance staff to evaluate both
the safety and performance of those practices. Often, enhancements can be made to either ensure
a safe lift or improve the ease and performance of the lift.

Figure 4-7
Rigging Fixture for a Control Valve Actuator
Lifting beams are used with rotors. They require preparation for each lift. The preparation will
usually involve setting the span for the lift points on the beam as they relate to the center mass of
the load. Figure 4-8 shows a sketch of a modification to a lifting beam that allows the adjusting
turnbuckle to remain attached to the beam between lifts. The turnbuckle weighed over 100 lb
(45.4 kg) and was awkward to assemble and rig to the beam. A minor modification allowed the
turnbuckle to remain in place after each lift, making the rigging safer and quicker.

Figure 4-8
Modification to a Lifting Beam That Allows the Turnbuckle to Remain Attached While Lifting
Synthetic slings are available as replacements for wire rope cables used for lifting turbine-
generator equipment. An example of when to replace an existing wire rope lifting cable with a
synthetic sling is when lifting the generator field. A long, heavy wire rope is wound around the
field for the lift. The cable is awkward and heavy, and part of the activity includes wrapping the
cable by hand. The replacement synthetic slings are light and easy to maneuver, making them a
safer rig. The wire rope cable is also used to lift one end of the field when the field is still in the

4-16
stator. The cable is worked around the field by hand. Again, this is an awkward and difficult
activity. The activity becomes more manageable with the use of the synthetic sling.
The EPRI report Guidelines for Using Synthetic Slings for Lifting and Rigging, 1007676, [13] is
available to provide guidance on the use of high-performance synthetic slings and also the
inspection and removal criteria for these slings.
4.2.3 Practical Methods for Efficient Handling of Certain Components
Improvements to existing rigging and lifting methods are easy ways to improve rigging or fixture
performance. The following four steps are involved in the evaluation and improvement process:
1. Observe the activity.
2. Interact with the personnel performing the activity.
3. Research industry improvements for the activity.
4. Redesign and/or integrate state-of-art improvements into the activity.
An example of a modification to an existing method and rigging fixture is shown in Figure 4-9
for generator field support.

Figure 4-9
Example of a Generator Field Support Modification
In the example, the bracket is assembled to the generator end shield and is used to support the
field when the bearings are not in place. Maintenance activities require some horizontal and
vertical movement of the field and, at times, some rotation of the field. A vertical adjustment to

4-17
the field position with the existing bracket was accomplished using jacking bolts. However,
horizontal (side-to-side) movement and any rotation proved to be difficult. Revisions to the
bracket assembly included:
1. Low friction pads inserted into the inner ring to allow rotational movement
2. Installation of horizontal jacking bolts for horizontal movement adjustments
3. Insertion of bearing surfaces beneath vertical jacking bolts for ease of horizontal movement
4.2.4 Special Turbine Tools
Data are accumulated beginning prior to the unit comes off-line and continuing until the unit is
on-line. Data collection begins with obtaining turbine vibration and operating data prior to the
units coming off line. Positional and clearance measurements are taken as soon as the sections
are disassembled and components exposed, and reassembly information is gathered and assessed
as sections are assembled and completed. Critical repair, replacement, and alignment decisions
are made from the information gathered. Therefore, it is essential that the data be accumulated
and analyzed and timely, appropriate action taken. The following are the essential elements of
data collection and analysis:
1. Recording Accumulating information
2. Verification Checking the data as reasonable and evaluating whether they are within
tolerances
3. Presentation Concise viewing of the data in a meaningful format
4. Comparison Trending against historical information
Often, some aspect of data collection occurs as part of the turbine outage critical path. Therefore,
any effort to reduce time in the appropriate phase is beneficial.
Automated data collection hardware and software are one way to reduce the amount of
information that is read, written, and transcribed when taking clearance measurements.
Electronic alignment gauges can help with the reading portion of data collection. A fully
automated system would record the information and store it for download.
Data are verified as either reasonable or within tolerance. Reasonable means that the readings
make sense and are reflective of what was expected. Tolerance evaluation requires knowing the
design size and tolerance and then comparing the readings. An automated system would compare
the readings taken with the design nominal size and the applied tolerance. Readings out of
tolerance are flagged for attention and disposition. The information is presented in a readable
tabular or similar format.
Data recorded are often compared to previous readings taken from the last inspection. A
complete system would include the ability to compare and trend current and historical data.

4-18
4.3 Scheduling Overhead Crane Time
The primary material handling device on the turbine deck is the overhead crane. It is used to lift
and transport turbine-generator components during disassembly, repairs, and reassembly. The
greatest use of the overhead crane occurs during disassembly. The second dense use period is
during reassembly. The best method to ensure effective use of the overhead crane is through a
coordinator. The coordinators responsibility is to:
Know the turbine-generator activity requirements - rigging plans/rigging preparation status
Set current activity priorities
Know where lifts/loads are going through the use of the turbine deck lay-down plan
Receive and schedule lift and transport requests
The coordinator then organizes the tasks with the crane operator for optimal utilization of the
crane.
The remote radio control of the overhead crane is a valuable asset during many of the transport
periods. The remote control allows the crane operator to be on the turbine deck and interact with
the turbine deck personnel while operating the crane. The crane operator becomes an effective
resource in a multiskill/cross-skill environment. The crane operator may assist in rigging
preparation and observing for clearances while operating the crane from the turbine deck.
As a safety, precautionary note, if a utility has more than one radio controller (box) for the crane
and if either box requires maintenance that will be done on-site, be sure that the crane is
disabled.
4.4 Moving Without the Overhead Crane
Secondary lifting devices that support the turbine deck overhead crane are easily integrated into
the turbine deck lay-down plan and maintenance activities. Pickers can be used outside the
overhead crane lifting area in locations such as separately mounted control valves. Installation of
jib cranes over valve locations can also supplement pickers in these locations. To effectively use
pickers, portable gantry cranes, forklifts, and other lifting devices requires space planning on the
turbine deck lay-down plan. Effective use of these secondary lifting devices reduces overhead
crane priority conflicts.
4.5 Special Storage Considerations
Material handling of turbine-generator components includes how they are transported and what
they are transported in. Design of the transport/storage devices should include an understanding
of activities to be performed on the component while it is in the transport/storage device. An
example of a design consideration is evaluating what maintenance activity can be performed

4-19
while the component is in a rack and then positioning the component at a working height in the
rack. Therefore, design considerations should at least include:
Ease of use
Access to component - single-item storage
Access to other components - multiple-item storage
4.5.1 Racks for Diaphragms
Diaphragm transport/storage racks should place the diaphragms in a vertical position, as shown
in Figure 4-10, with sufficient space between the diaphragms to allow access on both sides of the
diaphragm.

Figure 4-10
Example of a Diaphragm Transport and Storage Rack
Typical activities that can be performed on a diaphragm while it is in the transport/storage rack
are listed in Table 4-4.
Table 4-4
Activity Specifics
Sandblasting
Cleaning
Inspection Steam path, body, diameters (when assembled), roundness (when assembled)
Repairs Partitions (large diaphragm, few and minor), sealing areas (spill strip removal and
installation, packing replacement installation, horizontal joint repairs), crush pin
Fasteners Removal, thread repair

4-20
As shown in Figure 4-11, oil deflector racks can be constructed in a similar fashion as diaphragm
racks. The advantage of using oil deflector racks is condensing the space requirement for oil
deflector storage (vertical vs. horizontal) and access to the deflectors for measurements. The
following oil deflector rack example groups the oil deflectors together for a particular standard.
The oil deflectors are positioned so that workspace is available between the oil deflectors when
they are assembled.

Figure 4-11
Example of an Oil Deflector Rack
A similar style rack can be constructed for packing casings. Racks potentially decrease
diaphragm maintenance activities, reduce handling time, and reduce the space requirements on
the turbine deck for diaphragm storage.

4-21
4.5.2 Valve Stands, Rotor Stands, Mandrels, Try Bars, and Stub Shafts
Stands and fixtures are fabricated to accommodate specific valve maintenance activities. Figure
4-12 shows a simple fixture that holds a control valve stand in an inverted position to facilitate
inspections and maintenance measurements.

Figure 4-12
Example of a Fixture Holding a Control Valve
Manual rotation of rotors frees overhead crane support. Fabricated rotor stands with rollers
incorporated into the design as shown in Figure 4-13 allow hand rotation of the rotor when doing
the following activities:
Sandblasting
Inspections
Repairs

4-22

Figure 4-13
Example of a Fabricated Rotor Stand with Rollers
A bearing fitting mandrel as shown in Figure 4-14 can be machined to facilitate bearing fitting
for both tilt pad and journal bearings. The individual tilt pads from a tilting pad bearing should
be checked against a mandrel for proper curvature. The mandrel should be straight and round
within 0.001" (0.0254 mm), with at least a 63 microinch (1.8 micrometers) surface finish. The
mandrel diameter (B in sketch) should be equal to the actual rotor diameter plus the machined
bearing clearance. Each pad fitted to the mandrel should have a minimum of 80% contact. Fitting
is done by bluing the mandrel and then hand scraping the babbitt material at the contact points.

Figure 4-14
Example of a Bearing Fitting Mandrel to Check Tilt Pads
Cylindrical or elliptical bore bearings may also be fitted to a mandrel as shown in Figure 4-15.
The objective of fitting these bearings is to ensure clearance at the sealing bore of the bearing to
the rotor journal, which will prevent bearing contact to the rotor during operation. An elliptical
bearing has a horizontal clearance that is greater than the vertical clearance. The ellipse is
obtained by machining the bearing bore to the larger horizontal diameter (horizontal clearance
plus the journal diameter) with shims inserted in the horizontal joints of the bearing. The shim
thickness is equal to the horizontal clearance minus the vertical clearance. The shims are
removed and the bearing is reassembled to machine the sealing bore.

4-23

Figure 4-15
Example of a Mandrel to Check Cylindrical or Elliptical Bearing Bores
The mandrel diameter for an elliptical bearing should be equal to the actual rotor diameter plus
the machined bearing vertical clearance with a mandrel tolerance of +0.000"/-0.005" (+0.000/
-0.127 mm). The mandrel is blued and set into the bottom of the bearing. The indicated
isolated contact spots of the seal bore are carefully hand-scraped using a babbitt shaving tool.
A try bar is machined to check the alignment and wear of components that must maintain an
axial relationship to one another. For example, a try bar can be machined and used to check the
alignment and wear of a control valve sleeve that guides the control valve disc. The try bar is
machined 0.002" (0.0508 mm) smaller than the associated bushing design diameter of the control
valve stand. The tolerance for machining the try bar is 0.001" (0.0254 mm). The valve stem
and crosshead are removed from the control valve stand and the try bar inserted. A dial indicator
is set to sweep the inside diameter of the sleeve of the control valve balance chamber. The sleeve
and disc are inspected and replaced as appropriate if the total dial indicator reading exceeds a set
value.
4.5.3 Shell Racks, Supports, and Cribbing
Figure 4-16 shows an example of a shell rack for a HP upper inner shell. The rack places and
holds the shell in an inverted position. Inspection and maintenance may be performed to the shell
internal areas, horizontal joint, and sealing bores with the shell in this position. The inlet
expansion pipes are also positioned to be cleaned and inspected.

4-24

Figure 4-16
Example of a Rack for Holding an HP Upper Shell
Shells, casings, and hoods that are removed from the turbine are set in an elevated position on
the turbine deck. The height of the elevated position may be set for convenience of inspection,
maintenance of the horizontal joint, and access to the internal area of the shell, casing, or hood.
Some components, such as the HP outer upper shell, can be removed from the turbine still
loaded with horizontal joint bolts; the elevation of the shell is then determined by the length of
the bolt protrusion. Figure 4-17 is an example of fabricated shell supports that are used to replace
oak cribbing.

Figure 4-17
Example of a Fabricated Shell Support
The generator field and other large and heavy turbine-generator components are typically set on
oak cribbing as either a temporary or a maintenance setting. Oak cribbing may not only be large,
heavy, and awkward to manually position, but also its load bearing capability may be insufficient
for heavy load settings.

4-25
Figure 4-18 is an example of a support that replaces oak cribbing when doing generator field
removal from the stator. The removal procedure requires re-rigging the field at an interim
removal position. The field must be lowered, temporarily supported, re-rigged, lifted, and then
the removal process continues. A temporary support rig was fabricated for use instead of
manually placing cribbing for the interim re-rig. The rig uses common utility trailer jacking
roller assemblies that allow the rig to be rolled under the suspended field. After moving the
temporary rig into position, the jacking roller assemblies are swung to a storage position and the
centerline jack screw support is raised to contact the field as it is released for re-rigging.

Figure 4-18
Example of a Support for Generator Field Removal Without Cribbing
4.6 Bolt Removal Practices and Techniques
Many different shapes, sizes, and configurations of fasteners are used in the assembly of the
turbine-generator. The largest diameter and longest are usually associated with assembly of the
HP inner and outer shells. Other locations that use special access fastener features or tooling may
present unique challenges for assembly. Although they look different, are different sizes, and
require different assembly techniques, they have one thing in common: keeping the assembly
closed and tight during its duty cycle.
Assembly closure is a function of stretching the fastener and compressing the joint. The stretch
imposed on the fastener is a result of the material used, the size of the fastener, the load applied
during assembly, and an evaluation of the load applied in service. The fastener assembly design
stress and required loading determine the allowable preload. Typical allowable steel alloy
preload stress ranges are between 30,000 psi (206.85 MPa) (0.0010" stretch per inch of active
body)(0.0254 mm per 2.54 cm of active body) and 45,000 psi (310.275 MPa) (0.0015" stretch
per inch of active body) (0.0381 mm per 2.54 cm of active body). The techniques to impose the
preload and close the assembly are as varied as the fastener types.
Assembly methods used to stretch the fasteners are:
Mechanical turn of nut/sledge hammer
Heat Flame/hot air/ cal rod/induction
Hydraulic tensile direction/radial direction/reaction

4-26
The amount of stretch is determined by:
Measurement turn of nut/micrometer/ultrasonic
Torque wrenches/mechanical/hydraulic
Each assembly method has its advantages and disadvantages. Cold stretching or using
mechanical methods tend to gall the interface surfaces of the fastener, either the threads or the
load-bearing surface. Hydraulically tensioned methods stretch the fastener without galling but
require special fasteners. Thermal stretching requires the fastener to heat faster than the assembly
and measuring the stretch requires cooling the fastener, which makes the time to complete the
assembly cycle longer. Disassembling a hot assembly requires first cooling the assembly
sufficiently to gain a fastener heating temperature differential advantage. Table 4-5 provides an
accuracy comparison of the various preload methods. The most accurate and efficient method
should be chosen for critical closing joints, for example, main steam inlet flanges. Tightening
methods using power drivers are similar in accuracy to equivalent manual methods.
Table 4-5
Comparison of Accuracy Between Different Preload Methods [14]
Method Accuracy Method Accuracy
By feel 35% Computer-controlled wrench
below yield
15%
Torque wrench 25% Computer-controlled wrench
yield-point sensing
8%
Turn-of-nut 15%
Preload indicating
washer
10% Bolt elongation 35%
Strain gages 1% Ultrasonic sensing 1%
Knowing the joint configuration and assembly process is important when during component
disassembly. As an example, many HP and IP sections are designed with lower shells carried by
the upper shell and with the lower shell virtually unsupported. However, when maintenance is
performed, the lower shell is supported. Maintenance shims are inserted between the lower
shell and turbine pedestal structure before removing the horizontal joint bolting. If the
maintenance shims are not installed, the lower shell will drop when the horizontal joint is
unbolted.
The HP and IP outer and inner horizontal bolts are heated to disassemble the horizontal joint.
Then cal-rod heaters are inserted into the center bores of the bolting; the heating causes the bolt
to expand and lengthen so the nuts can be turned. The fastener should be cooled as soon as the
nut is loose to minimize heat buildup in the joint. Loosen the fastener nut at least two full turns to
prevent re-engaging the nut as the fastener cools. Horizontal joint distortion will normally open
further in the center than at the outer axial positions. Therefore, starting the joint unbolting at
both axial ends simultaneously and continuing toward the center allows the joint to open as the
bolts are loosened without re-engaging the fasteners.

4-27
4.6.1 Identifying the Necessary Personnel for Unbolting the Turbine-Generator
The number of personnel required for unbolting the turbine-generator depends on the process
that is being used. Casing bolts are very large and must be heated to relax the bolt tension. The
temperature of the casing bolt must be elevated to approximately 300F (148.8C) to relax the
tension in the bolt. The most common method of relaxing the tension on the casing joint bolts is
to use calorimeter (cal) rods to heat the bolts. Another method of relaxing the bolt tension is to
use gas heaters. The fastest method for relaxing the bolt tension is to use induction heating.
When using cal rods to relax the joint bolts, the mechanics work in pairs to remove the nuts. One
mechanic works above the horizontal joint, while the other works below the joint. The cal rod
method requires 3045 minutes to relax the bolt tension, so many bolts are heated at once. Both
sides of the casing (left and right) are worked concurrently; accordingly, four mechanics are
needed for each casing.
The cal rods can be shorted out while moving them, and it is often necessary to have an
electrician available to repair shorted cal rods during the disassembly process. The cal rods
should be in good working condition before starting the outage. For the cal rods to be effective,
they must be matched to the bolt for length and diameter. The operator must take care while
using cal rods so that the rods do not short out and cause an injury.
The hot-gas bolt-heating method uses an oxy-acetylene torch, compressed air, and a special gas
heating device. The torch heats the compressed air, which is then forced through a tube to the
bottom of the bolt. The bottom of the bolt is sealed off so that the hot air rises back along the
length of the bolt and escapes through an exhaust below the heating chamber of the tool. These
gas bolt heaters are called hot rods. The time that this method takes to relax the bolt tension is
between 1030 minutes. One mechanic works above the horizontal joint, while the other works
below the joint. Both sides of the casing (left and right) are worked concurrently; thus, four
mechanics are needed for each casing.
It is important to size the gas heater to the bolt to properly relax the bolt tension. It is also
important to monitor the heat input and airflow to get the temperature correct. The operator must
be extremely cautious while using the gas heater so that the torch does not start a fire.
Induction bolt heating is the fastest method of relaxing the bolt tension. In induction heating, a
rod is inserted into the center of the bolt and power is applied. The induction rod is sized so that
the bolt extension is achieved within a few minutes. A small bolt can be elongated in two or
three minutes, and a large bolt will take around five minutes to elongate. The induction heating
method is very accurate, and after the power is turned off, the bolt does not elongate further.
The induction rods are water cooled and have large power sources, which must be kept within 20
feet (6.1 m) of the rods. This method of heating requires one operator per power source and four
mechanics to work each side of the turbine to remove the nuts from the bolts. Two power sources
are used concurrently so that both sides of the turbine are worked together; as a result, the
induction heating method of bolt relaxation requires two operators and eight mechanics per
casing.

4-28
The operator must be careful not to overheat the bolt, so that the bolt temperature does not
approach the tempering temperature. A timer shuts off the power source to ensure that the proper
bolt extension is not exceeded.
The low pressure (LP) turbine exhaust hoods do not require bolt heating and, therefore, can be
unbolted quickly. The exhaust hood bolts are usually removed with pneumatic wrenches. Two
mechanics can work concurrently on each hood to unbolt it. The crossover pipes require two
mechanics per flange to unbolt. The crossover pipe flange bolts are small and can be removed
with pneumatic, hydraulic, or knocker wrenches. The LP turbine casings also have small bolts
that do not require heating to remove. Two mechanics can work on each side during the LP
casing disassembly. Both sides of the casing should be worked concurrently, so four mechanics
are needed for each LP casing.
The steam leads have small bolts, and each lead should have two mechanics working to remove
the bolts. Also the steam control valves can be worked using two mechanics per valve. The rotor
couplings can be worked using two mechanics per coupling as well. Special coupling bolts allow
the couplings to be disassembled quicker, but they still require two mechanics per coupling to
operate the hydraulic tool.
Generator bolting, like the LP hoods, does not require bolt heating and are a smaller diameter
than turbine shell bolting. Typical sizes may range from only 12" (2.55.1 cm) diameter for end
shield components. Therefore, disassembly can be quick, using pneumatic or hydraulic tools.
Care must be taken on reassembly when preloading these fasteners. The fastener material
strength is matched with the internal thread component that is usually plain carbon, non-alloy,
low-temperature, structural grade steel. The corresponding fastener rating is equivalent to a
Society of Automotive Engineers (SAE) Grade 5 bolting material (proof strength: 85 ksi [586
MPa]; UTS: 120 ksi [827 MPa]; YS: 92 ksi [634]). During an outage, it is easy to replace any
lost or damaged SAE Grade 5 bolts with a higher strength fastener from plant stores. Often, SAE
Grade 8 bolting material (proof strength: 120 ksi [827 MPa]; UTS: 150 ksi [1034 MPa]; YS: 130
ksi [896 MPa]) is used. If a stud-type bolt is replaced in this manner, the pre-load limit of the
original bolt should be applied to avoid overstressing the threads. For a through-type bolt, the
higher strength fastener can be pre-loaded to its prescribed standard.
It is necessary to have a crane operator for the entire disassembly period. There may also be a
designated rigger who works with the crane operator to supervise all crane lifts. The mechanics
who are used to unbolt the turbine components also assist with the rigging, lifting, cribbing, and
placing of turbine components.
4.6.2 Available Tools Needed
Many special turbine and generator disassembly tools are included with the purchase of the unit.
Examples are listed in Table 4-6. These tools are specific to the unit and must be kept in the
powerhouse during the units life. These special tools should be kept on the turbine deck and
should be locked in metal boxes to ensure that they are available when needed. During a forced
unit outage, it is important to be able to get to these tools quickly to begin the disassembly

4-29
process. It is imperative that the special tools are kept in good working order, and they should be
inspected before and after each use. Each tool should be marked with the turbine serial number
to avoid mixing them up with tools from adjacent units. Some special tools are too large to be
kept in boxes and should be placed in designated areas.
Each turbine-generator should have its own toolbox, and each toolbox should be clearly marked
with the unit number and/or turbine serial number. If it is necessary to borrow a tool from
another units toolbox, the tool should be placed back in the original toolbox at the completion of
the job.
Special tools are designed and used to aid in the collection of data during the turbine inspection.
These tools should be kept in the unit-specific toolbox for future outages.
Table 4-6
Category Specific Tools
Large special tools Rotor-lifting beams, wire rope slings, generator field skidpans,
generator stator trunions, bearing disassembly-lifting devices for
generators and low pressure turbines
Toolbox tools Casing jacks, casing guide bars, knocker wrenches, bolt heaters, bolt
extensometers, special hydraulic wrenches and wrench, adapters,
hydraulic coupling bolt tensioning tools, temporary rotor supports,
temporary coupling bolts, coupling jacking bolts, crossover expansion
joint lock bolts, valve try bars, valve lift measuring rods, EHC system
flushing blocks and flushing valves, bearing mandrels, valve
disassembly tools
Special generator tools Temporary rotor supports, end bell sealant pump, hydrogen seal
disassembly sockets and extensions, hydrogen line spool pieces
Designed unit-specific
tools
Rotor temporary thrust, shaft extension alignment tools, valve seat
lapping tools, oil line blanks, jack supports

Some turbines have temporary support keys that are bolted to the pedestals or standards next to
the permanent keys. These temporary keys should be cleaned and bolted to the pedestals at the
end of the outage.
Turbine bolt disassembly is performed by heating the bolt to relax the bolt tension. Resistance
heating has been used for many years to relax bolt tension. A newer and faster method of
relaxing bolt tension is induction heating. Induction bolt heating is up to 10 times faster than
resistance bolt heating. Induction heating is also used for generator retaining ring removal and
other special heating requirements. Induction heaters have special safety devices installed to
ensure that they do not heat the bolt past its unique tempering temperature.
One other bolt tensioning device that is used for turbines and valves is the hydraulic wrench.

4-30
4.6.3 Useful Tools and Techniques for Different Applications
The ability to effectively open a hot HP or IP section has been enhanced through the application
of induction bolt heating. Cal rod heaters and flame/hot air heating have inherent thermal transfer
limitations. The speed at which a fastener can be stretched without first cooling the joint/fastener
has increased through the adaptation of induction heating. Induction heating uses a high-
frequency device that excites molecular activity in the fastener, causing the fastener to increase
in temperature and length.
4.6.4 Bolt Removal Sequence
The removal of bolting on the turbine-generator should be performed in the correct sequence to
keep from damaging the hardware and to allow for the fastest possible disassembly. Before the
removal of bolting, many preliminary operations must be performed. A sequence of these
possible activities is shown below:
1. Remove appearance lagging.
2. Install crossover scaffolding.
3. Locate shell pocket jacks and all required rigging.
4. Remove bolting insulation.
5. Remove LP manhole covers and install ventilation blowers.
6. Remove crossover piping.
7. Remove exhaust hoods.
8. Remove joint bolt steam shields in LPs.
9. Remove packing cover upper halves.
10. Record rotor radial position.
11. Remove axial shell keys.
12. Remove internal keys.
13. Transfer from running to building keys.
14. Install scaffolding or build decking to allow access to bolting.
15. Apply penetrating oil to joint bolting and internal fits.
16. Disassemble leak-off piping and mechanical linkages on shell-mounted valves.
17. Disassemble steam lead flanges and separate flanges by jacking and blocking.
18. Perform rotor thrust check.

4-31
19. Tap and lubricate jackscrew holes.
20. Observe internal bolting warning plates.
21. Disconnect all thermocouples on upper half of casings.
During the cooldown period, arrangements are often made to air cool the turbine to reduce the
amount of time that the turbine is on turning gear. Air cooling requires that access ports and
drain valves on the turbine be opened so that air can be blown through these holes to assist with
the cooling process. Steam control valves can also be removed to assist with the cooling process.
These access ports and shell drains vary for each unit, and the engineer should determine the best
means of air cooling for each turbine casing.
Turbine casings are subject to thermal stresses, and relaxation of the metal occurs due to these
stresses. Creep also causes distortion of the casings. The casing distortion is greater in the center
of the casing than on the ends. The high stress on the bolting due to casing distortion requires the
outer bolts to be removed first and then work toward the center. Body bound (fitted) bolts or
tapered bolts must be removed before loosening any of the joint bolting. When unbolting casings
with both vertical and horizontal joints, the vertical joint must be unbolted first.
The process of unbolting the joint requires the loosening of bolts alternately from one side to the
other, working from the center toward the ends of the casing. If the nut will not unscrew from the
bolt after the bolt is relaxed by heating, the nut should be destructively removed. The fastest
method for removing nuts is by the carbon arc (air arc) process. The carbon arc process allows
the destruction of the nut without damaging the bolt.
The lower nuts should be removed from studs, which allows the stud to be supported by the
casing. The studs can later be removed from the upper casing after the casing has been supported
on cribbing on the turbine deck. This reduces the outage duration by allowing the studs to be
removed at a later time with other work performed. The turbine casing and joint bolts are very
hot during the disassembly period, and the workers must take precautions to keep from being
burned by the hot metal.
The generator is a composite assembly, unlike HP and IP turbines where the rotors are separately
supported in standards. The generator field is integrally supported within the assembly of the
stator. Generator end shields are the components that are designed to withstand the gas pressure
of the generator, seal the shaft, and carry the weight of the rotor. Therefore, during disassembly
of the generator, the weight of the field must be transferred from the end shields and its
components to the stator using temporary rigging. Precautions must be taken throughout
disassembly and reassembly to protect the stator end windings and the field during rigging and
transferring the weight of the field. A general sequence for the disassembly of a typical GE-type
generator is shown in the list that follows:
1. Remove the appearance lagging (removed prior to outage start).
2. Open the bushing box.
3. Remove instrumentation/connections (vibration probes, thermocouples).

4-32
The following steps are applicable to both the turbine and exciter ends of the generator. It is
assumed that the exciter has been removed, the turbine-generator coupling has been
disassembled, and the generator has been purged of hydrogen.
4. Remove the outer oil deflector upper half on both ends.
5. Remove the bearing cap.
6. Remove the bearing upper half.
7. Remove the bearing upper half.
8. Remove the hydrogen seal upper half.
9. Remove the inner oil deflector.
10. Remove the fan nozzle ring segments.
11. Unbolt and support the fan nozzle ring.
12. Remove the fan segments.
13. Remove the air gap baffles.
14. Install the field supports.
15. Remove the outer oil deflector lower half.
16. Remove the bearing lower half.
17. Remove the hydrogen seal lower half.
18. Remove the inner oil deflector lower half.
19. Remove the gap baffle.
20. Remove the lower end shield oil piping.
21. Unbolt and lower the lower end shield.
22. Install the skid pan and shoe, and remove the field.
23. Remove the inner end shield.
24. Unbolt and remove the hydrogen cooler heads.
25. Remove the hydrogen coolers.

4-33
4.6.5 Required Inventory of Bolts
Fastener usage should be reviewed as part of both the pre-outage and post-outage activities. A
review of historical data should show the locations and types of fasteners that have been used.
An analysis of usage should provide a list of what should be available during the upcoming
outage.
The matrix shown in Table 4-7 is derived from reviewing outage fastener usage. Each row
represents a different fastener size for the fastener type and use listed. Not all fastener data are
listed. The outage use information was reviewed and condensed to those fasteners that had high
replacement requirements. It is interesting to note that the types of fasteners requiring
replacement were in areas such as the diaphragm horizontal joint bolting, packing casing bolting,
and small flange bolting. Typically, these locations use smaller fasteners that are expendable
when stuck or easily replaced when damaged. Large fasteners for horizontal joint bolting require
replacement on occasion but not at the percentage or frequency interval of the smaller bolting.
Therefore, it is prudent to either stock, have available, or have identified and arranged quick
turnaround resources before the outage for the smaller fastener requirements. Larger fasteners
may require a different track.
Inventory reduction of larger fasteners can be accomplished in a variety of ways. Usually, larger
fasteners are unique in either size or material and, therefore, not readily available. Identifying
fastener-manufacturing resources before the outage is an approach to reduce stock. The
requirement to meet outage needs is the identification of replacement requirements early in the
outage. Higher temperature fasteners may require a unique material specification or size; for that
reason, these requirements should be identified and coordinated with the fastener manufacturer
before the outage. Another alternative is stocking the material and supplying it to the fastener
manufacturer.

4-34
Table 4-7
Outage Fastener Usage Record
Fastener Type Use # of Possible Uses
(Each row represents a
different fastener size.)
Historically Used
Socket head bolt Diaphragm joints 28
34
8
28
16
6
6
10
21
6
13
6
3
4
Hex head bolt Packing casing 32
48
8
8
40
16
3
6
8
3
4
4
Socket head cap
screw
Bearing joint 4
4
4
4
3
4
4
3
Through stud X-over flange 60
48
48
5
3
5
Tap stud Valves 20
10
32
15
2
7
4
6
Through bolt Leak-off flanges 16
20
16
5
4
4
A backup plan could be to identify and stock the largest fasteners in each material. Stocking the
fasteners with the largest diameter and length can provide emergency material to remachine the
larger fastener into the required smaller fastener.
4.7 Taking Axial and Radial Clearances and Their Use
Measurements taken during disassembly between stationary and rotating components provide an
insight into machine condition. It is possible to miss or not recognize machine problems if
opening measurements are not taken. Clearance readings are taken after the rotor has been set in
the design reference axial position and the turbine lube oil system has been shut down with rotor
couplings still assembled. The reference axial position is external to the steam path, and
measurements should be at the same reference position as the last time the rotor was assembled.
The reference position should be accessible even with an assembled section. A typical location
for measuring the reference axial position is in the standard or bearing housing where the back

4-35
face of the coupling or a step on the rotor can be measured on both the left and right sides of the
rotor. The accuracy and repeatability of all measurements are important to effectively describing
the condition of the turbine.
An alignment primer, dealing with both coupling alignment and internal alignment using a tight
wire or other measurement instruments, can be found in Volume 3, Balancing and Alignment
(1008856) [15] of this multivolume series. The primer covers significant issues that should be
considered when such work is being performed. In addition, a user manual [16] for coupling
alignment software (TGAlign) is available. Referred to later in this chapter, the program will
calculate the optimum alignment of rotors in a multi-rotor system, while minimizing the number
of bearing moves or by maximizing the number of bearing no moves. Rotor position, expected
alignment, shim changes, and other information are provided, which can be used to significantly
reduce outage time associated with coupling alignment during reassembly.
There is both an automated and manual version of this software. The automated version
calculates the best alignment given user-specified inputs and minimizes bearing moves to
achieve it; the manual version allows the user to click bearing moves using a mouse and observe
alignment changes as this is being done. Similar output reports are provided with both versions
of the software.
Additional discussion of TGAlign and general alignment procedures/practices can be found in
Section 4.8.
Clearance measurements are typically taken between the:
Diaphragm and the wheel
Packing and the rotor
Spill strips and the rotor
Diaphragms are seated in the direction of the steam flow using wedges between the upstream
side of the diaphragm and the shell to ensure diaphragm-to-shell contact when taking diaphragm-
to-wheel clearance measurements. Typically, most of the measurements are made only on one
side of the steam path and referenced to the wheel (the rotating component). The following
information is obtained from the diaphragm-to-wheel measurements or from observations made
during the measuring:
As-found axial position of the rotor in the steam path
Unusual transient expansions
Diaphragm dishing
Information regarding the need to reposition the rotor
Diaphragm-to-wheel positions are taken at a number of locations and may vary based on the
manufacturer, type, and design of the steam path. Typically, the clearance tolerances are tighter
for the upstream measurements than the downstream and are approximately 0.010" and
0.030" (0.254 mm and 0.762 mm), respectively. The actual design measurement should be

4-36
found on the rotor clearance drawing or from the last outage report. The following are typical
diaphragm-to-wheel clearance measurements:
Axial reading taken on the admission side of the bucket between the bucket cover admission
side and the discharge side of the diaphragm outer setback face
Taken on both left and right sides of the steam path
Information provided:
Determine rotor-to-diaphragm axial alignment
Verify bucket cover machining after bucket cover or bucket replacement
Identify shell or casing twisting
Used in conjunction with other axial readings to identify and monitor diaphragm
dishing
Axial clearance taken at the base of the bucket vane section between either (1) or (2):
(1) The bucket admission side axial sealing tooth integral to the bucket and the discharge
side diaphragm inner set back face
(2) The flat surface at the base of the bucket vane and the discharge side diaphragm inner
setback face, if there is no axial seal
Taken on left side of the steam path
Used in conjunction with the axial bucket cover clearance to determine rotor to
diaphragm axial alignment
Verify bucket machining after bucket replacement
Determine bucket drifting
dishing
Axial reading taken from the bucket admission side to the discharge side of the diaphragm
located at the bucket root radial seal
Verify bucket machining after bucket replacement
Taken on the left side of the steam path
Verify diaphragm machining
dishing

4-37
Radial reading taken from the bucket admission side machined fit at the base of the vane to
the integral spill strip incorporated in the diaphragm discharge side
Taken on both left and right sides of the steam path
Verify diaphragm machining
Verify sealing clearance
Axial reading taken between the rotor wheel admission side and the axial discharge side of
the diaphragm at the packing fit
Information provided: identify and monitor diaphragm dishing and distortion
Axial reading taken at the base of the bucket vane at the discharge side of the bucket to the
diaphragm admission side
Identify and monitor diaphragm dishing and distortion
Used with packing readings
Axial reading taken between the rotor wheel axial discharge side and the axial admission side
of the diaphragm at the packing fit
Taken on the left side of the steam path
Identify and monitor diaphragm dishing and distortion
Used with packing readings
The interstage packing rings are to be positioned to the steam sealing face in the packing groove
in addition to the rotor position and diaphragms being set. The packing is positioned against the
packing head or case steam seal face in end packing. All measurements are taken from the tip of
the long tooth packing to the strike point on the rotor land. Two axial measurements are made,
both on the left side (typically termed x and y readings) and both typically taken to assess
packing and rotor position. One is referenced from the turbine end and the other from the
generator end. (Older machines may require these readings to be taken on both the left and right
sides, due to distortion.) These readings are used to assess the axial alignment of the packing to
the rotor. A third reading is taken on both sides to measure the radial clearance. This reading is
used to identify packing tooth wear and misalignment.
Spill strip radial readings are taken on both left and right sides between the tip of the spill strip to
the bucket cover. The purpose of the reading is to identify spill strip tooth wear. Readings are
referenced to either the bucket cover admission or the discharge, depending on the stage sealing
design.

4-38
4.8 Required Rotor Radial Position and Coupling Alignment Checks
Rotor radial position measurements are taken to determine where the rotor is positioned in
relation to the stationary shells and oil deflector fits. The measurements are taken with the outer
shells in place and set on the running shims and are usually taken with sliding parallel gauges.
Oil deflector fit readings are normally taken with inside micrometers and are used to determine
turbine tight wire set points and to track rotor radial position and bearing moves when shim
changes are made to correct a coupling alignment problem. This information is critical. Every
effort should be made to ensure its accuracy and repeatability in order to minimize the potential
for rubs during the start-up of the unit.
A four-point, four-position alignment check of the turbine-generator couplings has been the
historically preferred method used to align the various turbine components to each other. The
alignment check of a coupling consists of a rim and a face reading with the coupling halves
separated from each other and in a free condition.
As shown in Figure 4-19, the rim reading (which is used to determine the extent of vertical and
horizontal offset of the coupling halves) is taken with a dial indicator mounted on one coupling
half and reading to the other coupling half. This reading is taken at each 90-degree rotation of the
coupling halves and should be verified as adding up. This means that the sum of the top and the
bottom reading is equal to the sum of the left and right reading, within 1 mil (0.0254 mm).
Readings should be taken at least two times to ensure that repeatability exists from one reading
set to the other. If it does not, the readings should be taken until they agree from set to set.
The face readings are taken to determine the vertical and horizontal angularity of the coupling
halves. These readings are taken at the top, bottom, right, and left sides of the coupling for each
90-degree rotation of the couplings (a total of 16 readings). These readings should add up in a
manner similar to the rim readings, that is, the average of the four top and bottom readings
should be equal to the average of the four left and right readings, within 1 mil (0.0254 mm).
Additionally, the face readings at each 90-degree rotation of the shaft should not reveal more
than a 1-mil (0.0254 mm) vertical or horizontal angularity change. If more than this is
experienced, either the accuracy of the reading should be challenged, or the coupling face has
run out, causing such a change to take place.

4-39

Figure 4-19
Coupling Alignment Nomenclature
Readings are taken and compared to design values to determine bearing adjustments that may be
required to align the rotors correctly relative to each other within specified alignment rim and
face tolerances. The entire rotor train is evaluated before making a single move.
Choosing the wrong component to move can result in multiple moves not only to obtain coupling
alignment but also to maintain internal clearances. The bearings are shimmed to acquire the
correct rotor position for coupling alignment. Vertical and horizontal alignment of the bearing is
accomplished by changing the shims between the bearing casing and the support pads in the
lower bearing half.
TGAlign software (available in an English version [16] and an SI unit version [17]), developed
by EPRI, is available as well as the alignment primer in Volume 3 to calculate the optimum
alignment for a multiple rotor system. Optimization is achieved by minimizing the number of
bearing moves or maximizing the extent of bearing no moves in order to achieve alignment.
Using this software, the user can model the shaft system in advance of an outage, decide what
rim and face limits are applicable, develop shim change input for the various bearings, and even
perform trial cases to assess what the potential bearing vertical and horizontal move limits may
be. During the outage (after the couplings are disassembled), the user enters as-found data.
Output reports provide recommended vertical and horizontal bearing moves, expected and as-
found radial position at oil bores or gland/shell bores, and shim change forms for each bearing.
The software is available in both automated and manual versions. The automated version uses an
optimization routine based on least square error and false position techniques to provide the best

4-40
achievable alignment with alignment limits while minimizing bearing moves to achieve it. The
manual version requires that the user click a move at each bearing and view the new or current
alignment as this process continues. Output reports are supplied similar to the automated version.
User manuals for TGAlign, which include a tutorial and sample problems, can be found on disk
4 of this four-CD set.
Typically, minimal bearing moves are made in a LP turbine because the stationary components
are fixed; it would mean movement of the inner shells and packing/glands if major moves are
required. Minimal moves are determined by as-left clearances in the diaphragms/blade rings and
the packing/glands. The generator and exciter are aligned as assembled components, thus
requiring no bearing move but movement of the complete assembly.
The HP and IP sections on GE machines may be more tolerant of larger moves, but this depends
on whether the shells and pedestals can be shimmed. If significant moves are made to the front
standard or HP bearings, the internals of the front standard may require alignment.
Siemens-Westimghouse-design HP and IP casings are typically aligned using vertical keys and
centering beams that are doweled to the standards. This method does not lend itself to making
moves to the shells because a significant shell move may require disassembly of the centering
beam and re-doweling it.
It is these factors that make the TGAlign software an excellent tool to solve alignment problems
while minimizing the bearing moves necessary to achieve it. Where multiple sections are
overhauled, alignment solutions can be sought in which certain bearings that are particularly
difficult to adjust are left undisturbed.
It should be noted that in many cases where single component inspections are regularly
performed to a unit, the overall alignment might become so poor that a complete tight wire
alignment of the unit becomes necessary. Outdoor units that experience sunlight year round tend
to require a major realignment every second or third overhaul of the machine.
The generator is aligned as an assembled component. The HP and IP sections are easier to align
for larger movements; the entire section can be elevated by shimming the soleplates of the
standards.
4.9 Checks to Assess Spare Rotor Compatibility
When ordering a spare rotor, the areas listed in Table 4-8 are important to ensure its
compatibility with the existing casings. Options to make the new rotor compliant are shown, but
it should be noted that these options may have limitations if the degree of deviation is too
excessive to correct.

4-41
Table 4-8
Checks to Determine Compatibility Between Original and Replacement Rotors
Rotor Component Area Modification Options to Facilitate
Compatibility
Coupling
Bolt circle
Fastener bore diameter
Spacer thickness
Rabbet fits
Line bore coupling holes.
Use replacement parts.
Machine or replace as necessary.
Machine or modify rabbet fit.
Bearing journals
Journal diameter

Journal ground length
Machine or weld build up rotor journals
or increase/decrease bearing babbitt
thickness.
Modify active length of bearing.
Oil deflectors Rotor diameter
Rotor axial position
Use replacement parts.
Machine the thrust bearing shims.
Thrust bearing Rotor Diameter
Axial position
Replace thrust bearing and shims.
Replace thrust bearing and/or shims.
Interstage and end
packing
Diameter

Number of lands
Land geometry
Machine the rotor or modify the
packing.
Replace or modify the packing.
Replace or modify the packing.
Expansion detector Diameter
Axial position
Adjust as necessary.
Adjust as necessary.
Steam path Axial position of buckets
Bucket covers
Replace the thrust bearing shims.
Machine the diaphragm, and/or modify
the spill strips.
Total rotor Total axial length Skim cut coupling faces for minor
corrections, or add coupling spacers.

5-1
5
TURBINE-GENERATOR CONDITION ASSESSMENT
When the critical path of an outage schedule is extended, it is usually as a result of unplanned
repair-replace-run decisions being made for certain critical components. Such components are
identified as those that cannot be easily or inexpensively replaced, thereby avoiding a prolonged
or unexpected delay to the critical path schedule. They are also fundamental to the reliable or
efficient operation of the unit, that is, they must be eventually restored to a serviceable condition.
It is at this phase that pre-bidding, contingency planning, and the existence of a sound
management strategy for the problem at hand can significantly reduce the potential downtime.
This section of the guidelines reviews and discusses the types of wear, damage, or fatigue
problems that can be expected for different portions of the turbine-generator and discusses
measures or contingency planning that should be considered in anticipation of their discovery. In
addition to addressing typical problems for the major turbine-generator subsystems, dedicated
turbine-generator technology (hardware and software) is referenced along with the basic
information and possible sources that are required to support an application.
Detailed procedures associated with the inspection and repair of turbine and generator
components are found in Volume 2. The various components can be found in the following
sections:
Section 1, Bearings
Section 2, Diaphragm and rings
Section 3, HP nozzle box/plates
Section 4, Valves
Section 5, Rotor/buckets
Section 6, Shell/casings
Section 7, Steam deflectors
Section 8, Generators
Volumes 6 and 7 provide detailed inspection and assessment criteria for typical forms of damage
associated with commonly operated types of HP, IP, and LP buckets.
The EPRI report Turbine Steam Path Damage: Theory and Practice, TR-108943-V2, [1]
provides a comprehensive reference on the current state of knowledge for major steam path
damage. This report presents information on the importance of limiting steam path damage.
There is a need to focus on this issue because failures of blades and disks in fossil and nuclear

Turbine-Generator Condition Assessment
5-2
turbines represent a serious loss of power. Problems other than shutdowns are efficiency losses
that restrict operation and reduce the maximum capacity of the unit.
5.1 Cleaning Without Disassembly
While the unit is assembled, turbine cleaning is limited to removing chemical deposits from the
turbine steam path. The chemicals, which are in solution in the steam, are often deposited
throughout the boiler, steam lines, heaters, and turbine. These chemicals build up in the nozzle
and blade passages over time and restrict the flow of steam through the turbine. The power
output of the turbine is nearly proportional to the steam flow through the turbine. If the deposits
build up significantly in the turbine, as much as 10% of the steam flow can be restricted. The
power loss over time is usually exponential and can be as high as a 10% loss.
The chemicals that are deposited in steam turbines are grouped into two categories: water-
soluble and non-water-soluble. The water-soluble chemical deposits can be removed from the
turbine when the turbine is shut down by reducing the steam temperature and pressure. This
process allows wet steam to wash the chemical deposits from the blades. This process generally
results in a recovery of a large percentage of the lost power.
The non-water-soluble chemical deposits can be removed from the turbine by chemically
cleaning the turbine while it is assembled or by disassembling the turbine and removing the
chemical deposits by grit blasting. The most economical method of removing these deposits from
the turbine steam path is chemical cleaning.
Chemical cleaning is done by injecting chemicals into the HP turbine at an elevated temperature.
The chemicals are carried within a foam to attach to the rotating components. This foam
dissolves the chemical deposits from the steam path and the deposits go into solution. The
turbine is filled to the bottom of the rotor with the foam and then put on turning gear during the
foam cleaning process to remove the chemical deposits from the upper half of the components.
The gland seals are put into service to keep any foam from escaping the casing. The foam is
liquefied and then drained from the turbine casings through the shell drains. The chemical
deposits are in solution as the liquid solvent drains from the turbine casing.
The non-water-soluble element that causes the largest steam flow reduction is copper. Copper
from heater and condenser tubing is deposited in the HP turbine as the steam temperature and
pressure are reduced. Copper deposits in the steam can cause a 10% steam flow loss in as little as
six weeks after a turbine major inspection. The chemical that is used to dissolve the copper
during the chemical cleaning process is an ammonia-based solvent. Corrosion tests have been
performed on turbine blades to ensure that the solvent will not cause stress corrosion cracking to
occur after the unit returns to service after being chemically cleaned. To date, foam cleaning of
the steam turbines is the most economical method of removing copper oxide deposits from the
steam path.
The foam cleaning process requires installation of mechanical connections to the inlet and
exhaust of the HP. Blanks must be installed in the cold reheat steam lines, and chemical holding
tanks must be installed. The first time the turbine is chemically cleaned, the cycle is long as a

5-3
result of the connections and tank installation. After these mechanical connections and tanks are
installed, turbine chemical cleaning can be performed in approximately five days.
5.2 Recommended Inspection and Testing Techniques
Nondestructive testing is performed on turbine-generator components to aid in identifying
conditions that may require the removal and replacement of the component, expose areas that
require repair or refurbishment, or assist in evaluating the serviceability of the component. It is
important to identify components that require corrective action early in the outage. Not all
components can be cleaned and inspected during the first days of an outage; therefore, the
priority and sequencing of inspections is important. The following considerations contribute to
the NDE priority selection:
Disassembly sequence
Cleaning sequence
Known and possible repair scopes
Repair duration
Reassembly sequence
Table 5-1 identifies typical components of a turbine-generator and lists the normally associated
inspection method. Each component receives a visual inspection in addition to the methods
listed. Nonmagnetic materials such as stellite, austenitic stainless steel, and Inconel, are
inspected with dye penetrant testing (PT). They appear in the matrix usually in combination with
another inspection technique for the balance of the component.
Only selected areas of a component may be inspected. Inspections should focus on first getting
the big picture and then focus on the specific areas. That is one reason why visual inspections
are important elements of the total inspection process. Many times, damage is severe and
obvious, and those areas may receive all the attention. However, damage to a component that
might cause problems after being returned to service is subtle and easily overlooked.
Observations and inspections should take into account the areas of a component that are subject
to:
Wear
Stress tensile and bending
Cyclic loading
Component geometry - stress risers and hidden areas
In-service damage
Manufacturing defects or deficiencies

5-4
Table 5-1
NDE Inspection Methods Used on Different Turbine-Generator Elements
Rotor HP IP LP Field Exciter
Coupling
WFMT WFMT WFMT WFMT WFMT WFMT = Wet
florescent
magnetic
particle testing

Journals
WFMT WFMT WFMT WFMT WFMT UT = Ultrasonic
testing

Body
WFMT WFMT WFMT MT = Dry
powder
magnetic
particle testing

Bore
UT & WFMT UT &
WFMT
UT &
WFMT
UT &
WFMT
ECT = Eddy
current testing

Buckets
WFMT WFMT WFMT PT = Dye
penetrant testing

Bucket pins UT
Tie wires WFMT
Tie-wire
holes
WFMT
Covers WFMT WFMT WFMT
Tenons WFMT WFMT WFMT
Stellite
shields
PT
Titanium
buckets

Rotor HP IP LP Field Exciter
Dovetails
WFMT WFMT WFMT
& UT

Fan rings WFMT
Main leads PT
Fan blades WFMT
Fan bolts WFMT
Retaining
rings
PT &
ECT
PT

Stationary
Components Diaphragms
Nozzle
Box
Shell
Outer
Shell
Inner Casing
Packing and
Casing Heads Crossover
Steam path WFMT & PT WFMT
& PT

Body WFMT WFMT
& UT

5-5
Table 5-1 (cont.)
Valves SV CV RHSV IV NRV
Ventilator
Valve
Equalizer
Valve
Seal rings WFMT WFMT WFMT
Horizontal
joint
MT MT MT
Vertical joint MT
Radial fits MT MT
Gib key fits MT
Flanges MT WFMT
ID areas MT MT MT MT
OD areas MT MT MT
Inlet
expansion
pipes
WFMT &
PT

Pre-warming
pipe
WFMT &
PT

Ventilator
Valve
Equalizer
Valve
Body
WFMT WFMT MT MT MT WFMT
WFMT &
PT
Anti-swirl
baffle
WFMT MT
Screen MT MT
Cover MT MT & PT MT
Stand

WFMT &
UT

Ventilator
Valve
Equalizer
Valve
Studs WFMT
& UT
UT
WFMT &
UT
MT &
UT
WFMT WFMT
Nuts WFMT WFMT WFMT WFMT WFMT WFMT
Spacers WFMT
Seat PT PT PT PT PT
Seat bolts WFMT
Seat pin UT
Seat pin
welds
WFMT
Pressure
seal head
WFMT,
PT, UT

WFMT,
PT, UT

5-6
Table 5-1 (cont.)
Ventilator
Valve
Equalizer
Valve
Stem
WFMT PT WFMT
WFMT &
PT
Shaft MT WFMT
Arm MT
Cap WFMT
Disc WFMT
& PT
WFMT WFMT PT PT
Flapper
valve

MT &
PT

Cap bolts WFMT
Bypass
valve
WFMT
& PT

Linkage
components
WFMT WFMT
Crosshead WFMT WFMT
Springs WFMT WFMT
Spring cans WFMT
Welds MT
Flange MT
Balance arm MT
Bushings MT

Fasteners
Horizontal
Joint Casing
Main Steam
Lead Flange
Bolts
Coupling
Bolts
Crossover
Flange
Body WFMT & UT WFMT UT & PT WFMT WFMT & UT
Threads WFMT WFMT PT WFMT WFMT
Spacers WFMT WFMT WFMT
Nuts WFMT WFMT WFMT WFMT WFMT

5-7
Table 5-1 (cont.)
Other Bearings Pumps Piping
Hydrogen
Seals

Babbitt bond UT UT
Babbitt bond
- edge
PT PT

Babbitt
integrity
PT

Impellers PT & UT
Shafts WFMT
Welds MT & PT
WFMT Wet florescent magnetic particle testing
MT Dry powder magnetic particle testing
UT Ultrasonic testing
ECT Eddy current testing
PT Dye penetrant testing
Close visual inspection is the starting point for the evaluation of generator components. Most
generator issues dealt with are mechanical or thermal in nature and often become electrical
problems after the dielectric strength of the insulation is degraded. Mechanical issues do not
always lend themselves to early detection by electrical test, but mechanical and thermal issues
may produce some visible effect that is discernable early in the failing process. The advantage of
early visible detection is normally that the condition is easier and less expensive to correct than if
it is given enough time to become an electrical problem. Examples of mechanical problems are:
Abrasion and chafing of insulation
Loose slot wedges or core iron
Movement seen in taped sections
Cracks in hard epoxy coatings
Table 5-2 presents a summary of visual inspections typically performed on generator
components.

5-8
Table 5-2
Visual Inspection Methods Used on Different Generator Elements

F
O
D

D
e
b
r
i
s

a
n
d

C
l
e
a
n
l
i
n
e
s
s

L
o
o
s
e

C
o
m
p
o
n
e
n
t
s

M
o
v
e
m
e
n
t
/
V
i
b
r
a
t
i
o
n

W
a
t
e
r

L
e
a
k
s

C
r
a
c
k
s

W
e
a
r

O
v
e
r
h
e
a
t
i
n
g

S
h
o
r
t
i
n
g

C
o
r
e

T
i
g
h
t
n
e
s
s

B
l
o
c
k
e
d

V
e
n
t
i
l
a
t
i
o
n

Stator bars X X X X X X X X X
Support system X X X X X X
Stator wedges X X X X X
Stator connections X X X X X X X X
High voltage bushings X X X X X X X X
Core end X X X X X X X X
Ventilation ducts X X X X X
Laminations X X X X X X
Key bars X X X X X
Field body wedges X X X X X X X
Retaining rings X X X X X X
Fans X X X X X
Field journals, sealing areas X X X X X X
Field windings X X X X X X
Collectors X X X X X X
5.2.1 Proof Test
A variety of electrical tests are available to assist in discerning the electrical state of both the
field and stator. One of the major test concerns is determining the condition or serviceability of
the insulation. One common test to determine if the insulation will contain the applied voltage is
the high-potential (HIPOT) proof test. Three areas of concern are associated with this test: what
type of voltage to use, what voltage level to use, and will the test damage the insulation?

5-9
A more uniform search effect is obtained when using an alternating current (ac) voltage, direct
current (dc) voltage being somewhat inconsistent. Direct current (dc) over-voltage testing can be
used but requires a voltage level increase (approximately 70%) over ac test voltage levels.
Choosing a voltage level above the operating voltage level establishes that at the time of the test
the insulation has not degraded to that dielectric strength to contain the voltage. Some margin is
then known to exist.
The challenge is setting the test voltage level so that the test ensures a sufficient margin to handle
operational transients without stressing the windings. The insulating material does not
significantly deteriorate during normal operating conditions or during normal operating
temperatures. Degradation of the insulating material typically is a result of concentrated effects
of abrasion, over temperature, vibration, and thermal changes. Again, the test voltage should be
set above the highest expected transient, for example, if the lightning arrestors are set for 120%
voltage, then the test should be higher than that to allow for unknown or unpredicted transients.
An actual test voltage may be 150% voltage to accommodate transients and unpredicted
degradation.
In the utility industry, the problem with the proof test is in the very nature of the test, and
generator proof testing has been the subject of much debate. If a 150% voltage test is done and
the insulation fails at a specifically weak area, the remainder of the insulation may have been
able to withstand 400%. The unit may have been good to above the highest expected transient
that was below the test voltage, but now the insulation is failed. The unit is no longer
serviceable; whereas prior to the test, it might have lasted considerably longer. The advantage of
doing the test versus finding the weak spot in operation is timing and being able to respond
during a planned maintenance outage, not during a forced outage that would probably occur
during a period of peak load operation. Therefore, because of the nature of the test and the
possibility of an insulation breakdown, it would be prudent when planning the test to plan for the
contingency of failure.
Other tests are available to aid in the evaluation and determination of the insulation system to
ensure serviceability. All require application of voltage across the insulation, but unlike a proof
test that is done above the rated voltage level, the others are done below the rated voltage level.
A proof test is a go/no-go (pass/fail) test, but the others may require interpretation of results by
comparing them to unit age, previous tests, known or anticipated conditions, and other data.
5.2.2 Megger Test
The megger is a test that measures insulation resistance. The megger (short for megohmmeter)
is a high-range ohmmeter (10,000 M or infinity) that contains a hand-operated or motor-driven
DC generator and resistance indicator used to measure the high resistance values. Megger units
are available in a number of voltage levels up to 2,500 volts; 500-volt or 1,000-volt units are
typically used. The megger unit applies this potential and then measures the leakage. In a
mechanical sense, this is similar to pressuring a piping system and checking the pipes for leakage
by timing the pressure loss. Any conducting paths within the insulating system being tested
result in current flow and a reduction in meter reading. A high reading does not necessarily

5-10
indicate that the equipment can withstand the operating or rated potential because the megger
uses a potential much lower than the rated potential.
The megger unit can be used to perform a dielectric absorption test. A dielectric absorption index
of the insulating material is obtained when the megger test is run for a longer period of time;
approximately 10 minutes is typically used. During this time, the megger unit will charge the
high capacitance of the insulation wall (polarize), and if the system is clean and dry, the
indicated reading will increase.
The ratio of the 1 minute and 10 minute readings is known as the polarization index (PI). PIs
above 2.5 for the stator and 1.25 for the field are considered acceptable. Recording and plotting
the periodic resistance readings will show trends that may indicate impending insulation failures.
5.2.3 Doble Test
Another insulating system test sometimes called a Doble test uses ac voltage to measure the loss
in watts. This test is also known as:
Power dissipation factor test
Power factor test
Capacitance-power factor test
The test measures both the capacitance and power factor of the insulation. The insulation power
factor is a ratio of watts loss to the charging volt-amps expressed in a percentage (W/VA x
100%). The losses are a combination of:
Power losses (resistance loss, I
2
R)
Corona losses
Ionization losses within the insulation
Losses due to the application of the ac voltage
A perfect insulator would be a perfect capacitor and, therefore, would have a power factor of
zero and no internal losses. The Doble test is a relative test, trending changes in the power factor.
A slow change over a long period of time is most likely normal, but a rapid increase in a short
period of time would not be and would indicate a potential failure. Performing the Doble test at
different voltage levels and at the same temperature and voltage levels of previous tests will aid
in providing accurate comparisons of the test data.
5.2.4 Other Tests
An ac impedance test is also a relative test done on field windings to determine the condition of
the insulation. The test is performed at various voltage levels to check the impedance of the
windings. The impedance is the vector sum of the inductive and capacitive reactance. The
impedance in a field is mostly inductive. A shorted turn in the winding lowers the resistance of

5-11
the winding, resulting in a slight increase in current. But the main action is a change in inductive
reactance. A change in this value, when compared to early tests at the same voltage levels, can
indicate shorted turns in the windings or an increase in the number of existing shorted turns.
The dc leakage test is another analytical tool to evaluate the insulation system. This test is
performed by application of an increasing stepped dc voltage to some predetermined level or to a
point where abnormalities are observed. The leakage is measured at each voltage. The two are
plotted to obtain a leakage current curve. The shape and slope of the curve are observed and
compared to other readings. Trends or changes in the curve can provide information regarding
the state of the insulation. The current leakage is a function of insulation ground paths, but it is
also affected by moisture and surface contamination. This test is used in conjunction with other
test data to evaluate the overall condition of the insulating system.
Additional tests can be performed to evaluate a specific area or function of the generator other
than the insulating system. A field turn-to-turn test can be performed with the retaining rings
removed to help identify the location of known shorted turns. The test requires a power source of
low dc voltage and high current capabilities. The power source is applied to the field through the
collector rings. The voltage drop on each turn is measured and compared. A low voltage drop
when compared to the other turns indicates a shorted turn. This test indicates only shorted turns
with the field at rest and does not locate any problems that would be evident when the field is at
rated speed.
A hydraulic integrity test can be performed on the water-cooled stator windings to determine the
integrity of the hydraulic attachments to the water-cooled copper conductors. Both vacuum and
pressure decay tests are performed after the windings have been dried. A vacuum is drawn on the
windings, and then the windings are isolated. The vacuum is monitored and recorded every five
minutes for approximately 2.5 hours. The leak rate is calculated after this time and should not
exceed 3.0 ft
3
/day (0.085 m
3
/day). The pressurization test using dry compressed nitrogen or air is
run for 24 hours while recording: pressure, temperature, and atmospheric pressure every hour.
The leak rate is calculated at the end of the test period and should not exceed 1.0 ft
3
/day (0.028
m
3
/day). Exposed areas may be inspected with snoop during this test to facilitate finding leaks
while under pressure. The air can also be replaced with helium or helium tracer during the
pressure test. A helium sniffer can then be used to aid in finding any leak location.
A shorted stator core lamination test can be used if there is evidence of damage to the
laminations. Laminations are tested for shorts by using an electromagnetic core imperfection
detection (EL-CID) test. The EL-CID test is usually done on large machines where a full level
loop test is impractical. The EL-CID test uses low energy to excite the core, wrapping several
turns around the core by passing cables through the bore and around the outside of the stator. A
magnetic sensor (a magnetic potentiometer invented by Chattock and known as a chattock) is
used to detect the level of magnetic flux on the core surface and determine the locations of the
shorted laminations.

5-12
5.3 In Situ Inspection
5.3.1 Economic Incentives Imposed by Deregulation
Turbine-generator (T-G) overhauls require complete disassembly to facilitate inspections of
locations that are not accessible when the turbine-generator is assembled. A significant amount
of the planned outage timeframe can be spent removing the turbine outer and inner shells. Often
disassembly exposes unexpected damage in critical locations that requires either repair or
component replacement, adding days or possibly weeks to the critical path.
An unplanned extension to the outage can have the same financial impact as a forced outageas
much as a factor of 410 times the consequential lost generation cost of a planned outage. In a
deregulated power production climate, the lost generation cost from a planned outage or an
unplanned outage extension results in a lost opportunity to sell power. The lost sale may be as
much as a factor of 10 greater than the incremental replacement energy cost. This moves the
planned outage extension cost from a soft cost in a regulated environment to a hard cost in a
deregulated environment. The motivation then is clearly to reduce the total time of planned
outages for overhauls and minimize the occurrence of unplanned outage extensions. In situ
inspection can contribute to both of these goals.
One of the primary advantages of an in situ inspection is the minimal disassembly required to
perform the inspection. An interim inspection of some turbine-generator locations can be
implemented without removal of the inner and outer shells by accessing the machine internals.
This is accomplished with an in situ inspection device inserted by means of alternative pathways
into the unit.
Similarly, in situ inspection can be used in advance of a planned outage to look at accessible
turbine-generator areas and provide warning of unanticipated damage. As a result, repair and
replacement activities can be more efficiently planned, minimizing the effects on the outage
schedule. In a forced outage or in a situation where turbine damage is suspected, in situ
inspection may provide a valuable first look for determination of damage type and extent in
preparation for repair.
For more information on in situ visual inspection, see the EPRI guide Interim Guidelines for In
Situ Visual Inspection of Inlet and Outlet Turbine Stages: Part 2: Experiences, Approaches, and
Improvements in Remote Visual Inspection, TR-114961 [18]. The guides focus is on remote
visual inspection (RVI) for examining the early stages of high-pressure steam turbine rotors and
the latter stages of low-pressure rotors.
The most commonly deployed tool for turbine-generator in situ inspections is the video probe.
Commercial systems that are sufficiently rugged for deployment as turbine-generator inspection
tools are available from Olympus, Everest-VIT, and others. Variations of this tool have been
used extensively for inspecting jet engine components and other rotating machinery.

5-13
5.3.2 Machine Access
Access to the critical HP and LP locations is accomplished with minimal disassembly via main
steam inlet flanges, governor or control valves, manways in the exhaust hood, or engineered
inspection ports. Some of these pathways are challenging and may require accessory equipment
to navigate. Deployment of a flexible video probe in a steam turbine may require the use of
support mechanisms to deliver the probe to the area of interest. In the case of an HP rotor, the
video probe has sufficient rigidity to be directed through the steam inlet piping to the vicinity of
the nozzle box area. However, navigation of the nozzle box and stationary blades for access to
the first stage rotor blades requires the use of a probe delivery device.
Figure 5-1 shows an EPRI-sponsored video probe system being used to inspect the first stage
buckets of a 550 megawatt, tandem compound, single-reheat, quadruple-flow steam turbine. The
entry point was the separation between the first set of upper-quadrants steam inlet flanges, which
were unbolted and separated approximately 4.5" (114.3 mm). The steam inlet pipe had a nominal
diameter of 4" (101.6 mm), and the total path length to the area of interest was 15' (4.6 m).
Although the initial path was horizontal for approximately 5' (1.5 m), it then transitioned to a 6'
(1.8 m) vertical run through a 2' (0.6 m) radius curve. The inlet chamber of the nozzles was at the
termination of the vertical path. Three nozzles were located in the in the upper half, and three
were in the lower half. After the inlet chamber was reached, the path made a 90-degree bend out
of the plane into the axial flow direction in the turbine, continuing approximately 2" (50.8 mm)
in the axial direction to reach the first stage nozzle blade positions.

Figure 5-1
Access Path for Video Probe Delivery Device

5-14
A remotely operated delivery device allows the probe to traverse voids that the probe would
otherwise fall into and makes it possible to lift the forward section of the probe for entry into
elevated orifices such as the steam inlet of the nozzle box area. After the probe is inserted in
close proximity to the stationary blades, the built-in articulation capabilities of the probe tip are
sufficient to maneuver it between blades to the desired vantage point.
Other less tortuous routes, such as those found in the LP section, may require only the use of
semi-rigid plastic tubing or a similar device to guide the video probe to the inspection area. At
least one utility has installed external ports for LP inspection to facilitate access to two adjacent
rows of blades via a single port. This eliminates the need to put an operator on scaffolding
between the inner and outer casing to access these areas.
5.3.3 Video Probe Systems
Typically, the video probe systems can be operated on ac or dc power, deployed from a storage
case, or worn on an accessory belt. The systems can be operated in stand-alone mode or used in
conjunction with a VCR (to provide a record of the inspection), an external monitor (to allow a
larger viewing audience), or other video device.
Fixed-focus systems are designed with a large depth of field and do not require the operator to
focus the probe lens. Optional, detachable tip optics are available to vary the field of view, depth
of field, and direction of view, if required. Some systems offer an articulating probe tip that
allows remote control of the tip optics (via a joystick device) for precise viewing of the area of
interest. The flexibility of the probe shaft allows it to be manipulated around obstacles,
eliminating the need for line-of-sight access to view a remote area.
Video probe systems are also available with the capability to measure object length and depth.
An on-screen point-to-point measurement (or other convention) provides an accurate length
measurement of a damaged area or a distance measurement between areas of interest. Accurate
depth measurements are typically determined using a shadow probe technique or a three-
dimensional stereo-image technique.
Typical environmental limitations restrict the use of the video probe to a maximum temperature
of 180F (82C), depending upon the system used. However, at least one manufacturer offers a
device to air-cool the probe, extending the operational temperature range to approximately 500F
(260C).
Although the initial purchase price of a high-quality video probe system is not inexpensive,
payback can be realized quickly in avoided turbine disassembly time and the associated lost
generation costs. Commercial inspection services are also available, alleviating the need for
capital equipment purchase by the utility.
More information on the video probe delivery device for in situ visual inspection of steam
turbine and combustion turbine machines is available in the EPRI report Demonstration of a
Videoprobe Delivery Device for In Situ Inspection of Steam Turbine and Combustion Turbine

5-15
Machines, 1004002 [19]. The report includes the development and demonstration of two video
probe delivery devices in an active steam turbine and combustion turbine machine.
5.3.4 Utility Experiences
In situ inspection is being used by several utilities to evaluate critical locations in the first stage
areas of HP rotors and the last stage areas of LP rotors. Typical detectable damage mechanisms
include solid particle erosion in the HP and water droplet erosion in the LP section. Foreign
object damage and cracking are also detectable. Examples obtained from the previously
mentioned remote access probe system are shown in Figure 5-2.

Figure 5-2
Examples from Remote Video Probe In Situ Inspection
Access to selected areas of the LP rotor is typically gained via manways and access ports in the
condenser hood. HP rotors are accessed by breaking the inlet steam line at the main steam flange
or through an engineered access port in the inlet steam lead.
As the technology continues to improve, utilities continue to implement probe delivery devices
to more remotely accessible areas of interest. These devices have been fabricated both by in-
house utility staff and by inspection companies (or in cooperation with them). Designs range
from simplistic to intricate and have been used with varying levels of success. It is reasonable to
expect that probe delivery devices will continue to evolve and will further benefit from the
involvement of inspection companies offering commercial services. The EPRI report
Demonstration of a Videoprobe Delivery Device for In Situ Inspection of Steam Turbine and
Combustion Turbine Machines, 1004002, [19] presents additional details on the system used as
an illustration of the technology.
The EPRI report Interim Guidelines for In Situ Visual Inspection of Inlet and Outlet Turbine
Stages: Part 2: Experiences, Approaches, and Improvements in Remote Visual Inspection,

5-16
TR-114961, [18] is recommended as a detailed reference with more information on the state of
the art for in situ inspection among utility users. Topics covered in the report include:
In situ inspection considerations for HP and LP rotors
Degradation mechanisms
Utility experiences with in situ inspection
Gaining access to areas of interest
OEM and commercial vendor inspection services
Probe delivery systems
Recommendations for development
5.4 Accelerating Different Types of Inspections
Turbine-generator maintenance requires that many inspections be performed during disassembly,
after disassembly is complete, and during re-assembly. These inspections are:
Visual inspection
Dimensional inspection
Metallurgical testing
Electrical testing
Nondestructive testing
The type of testing must be determined before the outage, and each test must be completed at the
proper time. The engineer should review and verify all test data for accuracy before proceeding
with the turbine disassembly or assembly. This allows a second chance to obtain data if an error
is found. It is important to be able to get to the equipment in order to perform the required tests
and inspections without moving the equipment any more than necessary. There are many ways to
perform inspections faster by using special tools, supports, and modular tenting.
During the turbine disassembly, the alignment of the shafts must be recorded. These alignment
checks were originally performed using precision mechanical measurements. Dial indicators
measured radial coupling alignment, while sliding parallels and micrometers measured parallel
coupling alignment.
As lasers became more readily available, they were incorporated in the data collection process.
Helium neon lasers have been used to speed up coupling alignment checks without the need for
precision instruments. The rotors still need to be uncoupled to perform the laser alignment
checks and many hours are still required to complete the alignment check of the entire rotor
train.
Strain gage alignment has been used to perform rotor alignment without uncoupling the rotors
and is much faster than the other two methods. With strain gage alignment, the rotor train

5-17
alignment can be performed with the turbine and generator still hot and with the lube oil pumps
running. The analyses that are required to perform strain gauge alignment are extensive and
make the cost high, but the results can be worth the effort.
After the upper turbine components are disassembled, the rotor-to-casing clearances must be
recorded. These clearance checks were originally performed using precision measuring
instruments. Better precision instruments have been developed, but these still generally require
manual reading of the instrument and recording the data on a data sheet. In the most advanced
systems, clearance measurements can now be measured with electrical instruments where data
can be stored digitally and later downloaded into a computer.
After the rotors are removed from the bearings, they should be set on motorized roller stands.
The motorized rollers allow the rotors to be turned while inspections are performed, which
reduces the inspection time. After the visual inspection, the motorized roller stands allow the
rotors to be turned while blast cleaning and nondestructive testing is performed. Without
motorized rollers, the work must stop to allow the rotor to be turned with a crane or by
mechanical means.
The stationary components can be small diaphragms (impulse design) or large blade rings with
many stages (reaction design). If the turbine is of the impulse design, specially designed
diaphragm racks should be used for visual inspection, blast cleaning, and nondestructive testing.
Diaphragm racks can contain many diaphragms and allow access from both the admission and
discharge sides of the diaphragm. Diaphragm racks allow the cleaning and inspections to be
performed in batches and keep the diaphragms in sequential order.
If diaphragm racks are not used and the diaphragms are laid on the floor, a crane must be used to
turn the diaphragms over, which uses more crane time than if diaphragm racks were used.
Because the crane is used more than any other tool during the turbine overhaul, if blade rings are
set on end to give access to the blades while they are being blast cleaned and inspected, this can
reduce both the demands on the crane and a potential source of delay in terms of cleaning.
Monorails can be used to support the turbine components while the work force is performing
visual inspections, blast cleaning, and nondestructive testing. The setup of a monorail is time
consuming, and the monorail takes up a great deal of floor space. During the planning stage, the
planner should determine if the use of a monorail system would benefit the outage in order to
determine if it is worth the cost involved. Many nuclear units use monorail systems because of
the large components that must be handled.
5.4.1 Defect Sizing and Implications of Results
Defect detection and sizing is a critical element of nondestructive evaluation (NDE), especially if
the defect is subsurface and cannot be directly observed and visually mapped. Most often, sizing
and mapping of subsurface defects will be done with UT, while visual, MT, or PT methods are
used for surface indications. On occasion, radiographic testing (RT) is used to map subsurface
indications. Some of the constraints in sizing and mapping defects are listed in Table 5-3.

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Table 5-3
Sizing and Mapping Constraints Associated with NDE
Item Note
Indication/defect properties Size: estimated versus true, location, shape, orientation, sharpness,
type, repeatability,
Surface condition
Part geometry
Part complexity
Metallurgical condition Grain size, porosity, inclusion content, precipitate dispersion
Selection of NDE method
Viewing conditions
Operator performance
PT variables Pre-test cleaning, test conditions temperature, type of penetrant,
penetrant dwell time, penetrant removal, developer dwell time
MT variables Magnetizing procedure (ac, dc, flux density, flux orientation),
Permeability and retention of material
UT variables UT equipment (transducers, amplifiers, display), transducer shoes
(near-surface noise, reflection and retrieval angles), procedure
(calibration, couplant, wave-length), flaw reflectivity
RT variables Contrast and sharpness, equipment (output, source types, source
size), film type and processing, procedure (energy, filters, exposure
time, scattering, absorption)

It is generally beneficial to create an NDE test block prior to the outage and testing. A test block
takes into account the material and part geometry and is used to determine the various correlation
effects.
For UT, the test block should also include defects of known size and location. Equivalent flat-
bottomed holes (EFBH) are often used as an artificial discontinuity. The echo indication from the
EFBH is set at some convenient reference amplitude, and any indication is interpreted in
reference to it. Machined notches are also used. The NDE procedure to search for indications is
then developed and qualified. The ability to detect and size a material flaw directly impacts the
ability to evaluate a components remaining useful life. The ability to identify clusters of
indications is also used in evaluating components. Calibration blocks can be created to verify
system operation before testing. For example, a calibration block may have an artificial
discontinuity machined as the reference reflector and also have a surface the same contour as the
rotor bore.
Determining the size and location of indications is an essential part of evaluating a components
condition and predicting its serviceability and remaining useful life. The five elements that
support a component evaluation model are:
Operating history and projected operation
Geometry

5-19
Material properties
Stress analysis
NDE
Applying operating history and material properties to a stress analysis of a component can
provide the critical indication size to be searched for on initial inspection. Examples that are
related to specific blade designs are provided in both Volumes 6 and 7 of this guidelines series
[20, 21]. Further examples are shown in these volumes of how NDE results from the inspection
can provide input into the stress analysis to determine useful remaining life. Consequently,
locating, correctly sizing and reproducing results (in subsequent inspections) are important
elements in an overall component evaluation program.
5.5 Cleaning Coated Versus Non-Coated Parts
Coatings are applied to protect the base material from the detrimental effects of erosion or
corrosion. The coatings can be thermally sprayed, alloyed, galvanically, or vapor deposited onto
the surface of the parent metal in a thin layer and, in most cases, are applied to the unassembled
component. Coatings are often applied with service requirements equal to the life of the
component; therefore, it is not often desirable to remove them during an outage. The conditions
requiring coating removal would include repairing the base material or removing a damaged
coating that, if left in place, might cause more damage to the base material. Nevertheless,
cleaning a component prior to inspecting it during an outage is desirable. For non-coated parts, a
variety of global and local processes are available. Table 5-4 identifies processes that can be used
on both coated and non-coated components.
Table 5-4
Cleaning Processes Used for Coated and Non-Coated Components
Process Coated Non-Coated
Grit blasting
Aluminum oxide X

Glass bead
Reduced pressure
X
Hydroblast X
Local
processes

Hand stoning X
Abrasive cloth X
Wire brushing X X
Chemical cleaning X

5-20
5.6 Coating-Removal Techniques
Typically, a protective coating on a component is removed to facilitate repairs to the base
materials. This may be the case with coated diaphragms. The coating can be completely removed
during the grit blasting process or can be selectively removed during the repair process using
abrasive discs.
Preventing damage to surrounding areas or the base material is always a concern when removing
coatings. The problem with grit blasting is possible ricochet damage if the blasting process is not
closely monitored when a tenacious coating is being removed. Heat buildup is a concern when
attempting to manually remove coatings. Using a new disc on a hard coating will break down the
sharp abrasive disc material quicker than on the base metal. The cutting action is reduced;
therefore, the discs should be changed often before they dull and cause localized overheating of
the base metal.
5.7 Sampling and Analyzing Deposits
The consequence of corrosion to the back end of the turbine is the damage complement of what
solid particle erosion represents to the front end of the turbine. Both damage mechanisms are a
result of impurities being carried into the turbine. Solid particles carried into the turbine do
erosive damage to the turbine components if the correct angle of attack and velocity are present.
Impurities soluble in steam are carried to the back end of the turbine and deposited on the turbine
blades as the steam loses its ability to hold the impurities in solution. Impurities come out of
solution as the pressure and temperature of the steam decrease; therefore, deposit chemistry may
be different along the steam path of the LP section.
Deposits in a pure impulse stage are on the stationary blades and not the rotating blades.
As the percent stage reaction is increased, the impurities start to deposit on the rotating
blades as well as the stationary blades. For a 50% reaction stage, the deposit is about
equal on the rotating and stationary blades.
Some deposits are water-soluble and will not accumulate on stages operating in the wet
region. The deposits on the last few stages in the LP turbine of fossil and nuclear units
and in the HP turbine of the nuclear units are not water-soluble. In some fossil power
plants, copper, which is not water soluble, will deposit in the HP turbine. During the
overhaul, deposit samples should be collected and analyzed to assist the chemist in
deciding on the proper boiler treatment. [9, p. 418]
Obtaining samples can begin as soon as the outsides of the LP section diaphragms are exposed.
Observing the LP diaphragms in-place can reveal a deposit color span from the inlet to the last
stage. Samples can be taken from both the diaphragm partition and the bucket surfaces. Using an
envelope and a stainless steel spatula is an easy way to scrape the samples off the component.
Samples should be adequately marked to reflect unit, date, and other general identifying
information as well as location including stage, suction or discharge side, and stationary or
rotating component. The down side of sampling during an outage is that the deposits have
already occurred from the operating condition. On-line sampling can provide insights regarding
the part of the operating cycle in which the contaminants are being carried into the section.

5-21
As outage intervals increase, significant damage may have already occurred by the time the
component is inspected. Consequently, there is a benefit in monitoring both section inlet
chemistry and discharge impurities. For example, NiCrMoV rotor steel, AISI 422 stainless steel,
and AISI 403 stainless steel are all susceptible to stress corrosion cracking (SCC) if certain
conditions are present. Discovering during an outage that SCC has progressed far past the
incubation period is not a pleasant surprise. Instead, it is better to know and monitor for
impurities such as sodium that could produce SCC for the materials and stresses present. A
monitoring program should also include watching for other impurities such as chlorides that may
cause corrosion fatigue or cycle fatigue that originates at a corrosion pit.
A deposit-sampling program is important to identify either the cause of a corrosion-related
problem or the potential for one; however, sampling is only one tool. It should be used in
conjunction with a monitoring program.
5.8 NDE of Turbine-Generators and Collecting Boresonic Data
5.8.1 Turbine-Generator Nondestructive Evaluation Techniques
Periodic nondestructive evaluation (NDE) of steam turbines and generators is necessary to
ensure continued safe, reliable operation. Inspection of these components was introduced by the
original equipment manufacturer (OEM) in the mid1950s, and today there are a number of
vendors performing NDE inspections including OEMs and independents. Inspections range from
ultrasonic inspections of the rotor bore surface (boresonic) and disk blade attachment to
magnetic particle and dye penetrant inspections of rotor peripheral surfaces, blades, and blade
attachments.
There is a wide range of published literature on available NDE techniques; however, this
material may not be easily accessed by the power plant engineer who often has to make decisions
using limited information and in a short period. On the other hand, the NDE service provider is
often not fully aware of the problem associated with a particular part of the turbine. They may
suggest using inspection techniques that might be insensitive to the type of damage that is
important or, alternatively, propose to use a technique that yields more data than are necessary to
perform an adequate life assessment. The first course of action could lead to component failure,
and the second may lead to unnecessary expense.
The EPRI report NDE Guidelines for Fossil Power Plants, TR-108450, [22] is recommended as
a more detailed reference of techniques for inspecting critical components in the power plants.
Each section provides historical information about a component, damage mechanisms, typical
inspection locations, recommended inspection techniques, required preparation and support
requirements, estimated inspection time, permissible flaw sizes, recommended analytical
techniques, references, and related literature.
Section 4 of the report specifically addresses steam turbine inspection techniques and discusses
rotor bore, turbine disks, attachments, and shaft outer surface inspections, as well as inspections
of rotating blades including shrouds, tie wires, and tenons.

5-22
In addition to Section 4, EPRI guide Remote NDE Technology for Steam Turbines, 1006814,
[23] identifies the potential for remote NDE technology for steam turbine inspections and the
assessment of alternative surface preparation techniques for effective inspections. The report also
refers to emerging NDE technologies that may be adaptable for remote inspections.
5.8.2 Collecting Boresonic Data
Boresonic inspections are performed on both turbine and generator rotors. The typical OEM
recommendation is to perform turbine rotor bore inspections after the first 10 years of service
and subsequent inspections at an interval based on the inspection results, often equaling the
initial inspection interval. Generator rotors are recommended for first inspection after the first 20
years of service or as a function of how frequently the generator is cycled on an annual basis.
The information required to evaluate the results of a boresonic inspection is dependent on who is
performing the inspection and what specific information they already possess. The four major
groupings of information required to evaluate boresonic inspection results are:
Inspection results
Rotor geometry
Material information
Operating data
If the rotor OEM is performing the boresonic inspection and evaluating the results, they will
posses three of the four required areas of information. For example, the rotor OEM possesses the
rotor geometry and all the original rotor non-aged material properties. To complete the
assessment, the rotor OEM may need to acquire only a cursory view of operating data. If
someone other than the rotor OEM is performing the boresonic inspection and evaluation, all the
information required will need to be obtained.
The inspection results are a product of multiple NDE activities, each playing a critical roll in the
evaluation. Each NDE activity provides information for the rotor life analysis and remaining-life
determination. Honing or polishing the bore to a 63-microinch (1.6 micrometers) finish or better
before the inspection begins prepares the rotor bore. Sandblasting prepares the rotor periphery
for inspection.
The rotor bore is both visually and MT inspected. MT inspection will provide at bore
discontinuities or very shallow subsurface discontinuities. Rotor bore discontinuities are
extremely important because the maximum tangential stress occurs at the bore surfaces. The
rotor stress reduces rapidly away from the bore.
The bore UT will provide the most detailed information in the evaluation of the rotor.
Near-surface and near-field noise effects limit UT data to distances no closer than 1/81/4"
(3.56.4 mm) from the bore surface. Sound attenuation and rotor geometries tend to also limit
the depth of the search to approximately 6" (152 mm). The rotor may also be UT inspected from
the outer periphery for additional look in data. Information included with the mapping of any

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UT-discovered indications and rotor geometry required to determine rim loads and metal
temperatures for a stress analysis are itemized in Table 5-5.
Table 5-5
Support Information Required to Interpret UT Data
Radial distance from the bore surface
Axial location from the rotor reference end
Angular reference

Information That Should Be
Included with Any UT-Discovered
Indications
Three-dimensional size, numbers, and clustering information
Rotor Geometry Required to Determine Rim Loads and Metal Temperatures
Bore Bore diameters, bore lengths and axial reference location,
bottle bore transition taper and radius
Periphery Rotor body diameter, length, and axial position, rotor wheel
width, diameter, and axial location, bucket length and mass
(total attached to wheel)
Rotor and stage seal geometry Rotor body at seal, seal height, clearance, length of seal,
number of teeth, axial clearance between seal and wheel,
pressure drop across seal
If rotor and assembly drawings are available, much of the above information can be obtained
prior to the outage and confirmed as necessary during the outage. Any spare, new, or used N
(shaft end) packing end, interstage packing, seals, or buckets may provide sufficient steam path
and stage loading modeling information prior to the outage.
It may be necessary to obtain rotor bore samples to determine the rotor chemistry and material
data. Samples may be taken from the rotor coupling face (non-aged) or rotor bore (service aged)
at either single or multiple locations to provide creep information. The samples can provide a
number of material properties:
The rotor tensile property of yield strength may be used during analysis in fracture
assessment in the plastic zone adjustment of the indication (crack), in flaw linking, ligament
rupture, etc.
The rotor fracture toughness (K
IC
, a measure of critical stress intensity) data are used to
determine critical crack size.
Charpy V-notch (used to provide fracture appearance transition temperature [FATT] data)
and J-integral (parameter used to describe stress-strain field in plastic analysis of the yielded
zone of a crack) specimens taken provide temperature-related toughness data.
Material creep properties are required for the higher temperature rotors that are operating
above 40% of their melting temperature in absolute temperature (this range is typically for
rotor stages > 900F [> 482C]). Creep damage (material plastic flow) is a function of the
material, operating temperature, time, and stress.
Operating data may also be required for the rotor analysis. Operating data are used in the damage
accumulation model of the analysis and the remaining life prediction. A history of steam
temperature, pressure, rotor starts, ramp rates, operating projections, and other data provide the
details for a remaining life assessment. Future or planned component utilization is also important

5-24
as an input for life prediction until the next planned inspection interval, or the data may be used
to plan the next inspection period.
5.8.3 EPRI-Supported Rotor Boresonic Inspection
Over the years, EPRI has undertaken many programs to evaluate the inspection technologies
available to the industry. Probably the most recognized is the program to evaluate techniques for
performing ultrasonic inspection from the bore surface (boresonic) of steam turbine and
generator rotors. During the period immediately after the TVA Gallatin rotor failure in 1974a
failure that was ultimately determined as caused by a crack on the bore surfaceorganizations
that had experience in rotor inspection began to develop and implement techniques for inspecting
rotor forgings from the central bore hole. Prior to that time, only the OEM had been able to
perform the inspection. During this period, the number of vendors performing the inspection
increased, and although the inspections they were performing were similar in nature, variations
did occur. Utilities that earlier had only their OEM to rely on to perform the inspection now had
several vendors to choose from, and each claimed to be better than the last.
In the early 1980s, EPRI developed a program to evaluate the inspection systems that were
rapidly being deployed to meet the needs of the utility industry. A series of test blocks were
designed with flaws fabricated in them to resemble the types of flaws thought to exist in rotor
forging. To evaluate the test blocks, utilities would urge their vendors to participate in the
program by performing a blind test of the test blocks and have their results evaluated and
reported by EPRI. That program is still in effect today, and by the mid1990s, most of the
domestic companies known to provide boresonic inspection services had participated. The
following reports and system evaluations provide a good foundation for understanding boresonic
capability as it is applied today.
The EPRI report Rotor Boresonic Inspection Guidelines [24] is recommended as a detailed
reference. It provides guidance for planning and implementing a viable rotor bore inspection
program for steam turbine and generators. It also presents information useful to making a run-
retire decision on rotor use. Sections in the report cover:
History, including the Gallatin failure
Rotor material
Boresonic inspection principles
Discussion of various inspection systems (from a survey)
Description of the boresonic performance demonstration plan
Conclusions and recommendations for performing an inspection
Also developed by EPRI in the 1980s was a boresonic inspection data evaluation DOS-based
computer program, SAFER (Stress and Fracture Evaluation of Rotors), used to analyze the data
obtained from turbine-generator boresonic inspections and evaluate the remaining life of these
rotors. In 2004 EPRI released SAFER-PC (Stress and Fracture Evaluation of Rotors- Personal
Computer), product number 1010003, with numerous upgrades.

5-25
SAFER-PC combines transient thermal-elastic finite element stress analysis, fracture mechanics,
material property data, and the clustering and linking of surface defects identified from
nondestructive examination (NDE) data to assess the remaining useful life (RUL) of steam
turbine or generator rotors. SAFER-PC can also perform probabilistic analysis of remaining life
and material creep. It includes modules that allow imported boresonic NDE data in ASCII format
to generate a flaw file, and a flexible approach to curve-fitting fracture toughness data is also
available. SAFER-PCs powerful user interface enables the program to be run on a number of
current operating systems, with a variety of options for displaying and archiving analysis results.
SAFER-PC can be used to assess the remaining life of critical rotating equipment in life-
extension studies, potentially savings millions of dollars in replacement rotor costs. The program
can be used to reduce the uncertainty in risk analyses of older turbine-generator rotors, reducing
the possibility of rotor burst that is an issue involving both a safety and consequential cost. Many
plants are being cycled more frequently with larger daily variations in steam inlet temperatures.
SAFER-PC can evaluate the increased rate of damage associated with this mode of operation,
enabling a more accurate assessment of the costs and benefits of flexible plant operation.
The new version of SAFER, SAFER-PC Release 2.2, 1013044, [54] includes improvements to
the user interface developed as a result of the May 2004 user training held in Charlotte, North
Carolina, were formally incorporated in the official software release.
5.8.4 Boresonic System Evaluation Procedures
A boresonic system evaluation begins with the member utility making a request to sponsor a
particular inspection vendor. The evaluation blocks are then shipped to the participant where a
series of 1525 scans of the block is performed. At the end of the inspection phase of the
program, the participant is provided with a map of the flaw locations. Included are several
locations where either geometry reflections exist or there are no flaws at all. The boresonic
measurements taken by the vendor that describe the flaws are sent to the EPRI NDE Center for
statistical evaluation. The mean value and standard deviation for all scans are computed for each
dimension included in the study for the 70-odd flaws in the blocks. A linear least squares fit of
all the data, for each measured dimension, and for each defect type is then used to determine the
best fit of the measured values versus the true dimension. The linear best fit is represented by a
slope, intercept, correlation coefficient, and the root-mean-square (rms) error.
The slope and the intercept are indicative of the systematic error. The correlation coefficient is a
measure of the strength of the linear relationship between the true and indicated value. Standard
deviation and rms error are measures of the spread and accuracy (relative to the best fit line),
respectively, in the data.

5-26
Further details associated with specific inspection vendors can be found in the following EPRI
reports:
NEI Parsons Ltd. Boresonic Inspection System Evaluation, TR-102126, [25].
Northeast Inspection Services, Inc. Boresonic Inspection System Evaluation, TR-102256, [26].
WesDyne International UDRPS Boresonic Inspection System Evaluation, TR-106234, [27].
General Electric Company Boresonic Inspection System Evaluation, TR-107174, [28].
Reinhart & Associates, Inc. Boresonic Inspection System Evaluation, TR-108423, [29].
Boresonic System Performance Guide, TR-104355, [30] provides a comparison of all system
evaluations prior to 1994.
5.8.5 Inspection of Boreless Rotors
Nondestructive examination is generally less essential for solid (boreless) turbine rotors than for
bored rotors because stresses are lower without a central bore hole. Occasionally, situations arise
in which examination of a boreless turbine rotor is not only advisable but essential to maintain
confidence in the rotors capacity for continued safe operation. Ultrasonic examination of rotors
from their central bore holes has become an accepted in-service inspection method throughout
the utility industry. Without a bore, ultrasonic examination of the rotor must be conducted from
the outer periphery, a task that is made difficult by the periphery geometry and lack of a
continuous, uniform surface from which to conduct the inspection.
Boreless turbine rotors can be inspected reliably if the utility is willing to invest the time and
effort needed to conduct multiple inspections from the limited surfaces that are available for
transducer placement. Multiple direction angulation techniques must be used to inspect regions
that are otherwise inaccessible. To maintain sensitivity, calibration-correction factors must be
applied to account for the fact that the beam cannot be introduced orthogonally to the major
dimension of the flaw, which, on the most conservative assumption, is assumed to lie in a radial-
axial plane. Correction factors must also account for the possibility that the flaw does not lie in
the center of the beam where sensitivity is optimized. Each test must be carefully designed to
cover a specific region where normal inspection procedures cannot reach, and sensitivity
corrections must be used to analyze the data and estimate reflector sizes properly.
The EPRI report Guide for In-Service Ultrasonic Inspection of Boreless Turbine Rotors and
Other Solid Shafts, TR-101836, [31] is recommended as a reference document. It presents details
on methods of inspecting boreless rotors as well as determining appropriate inspection angles
and corresponding sensitivity correction factors.
5.8.6 Inspection of Steam Turbine Disk Blade Attachments
Although many innovative design changes have been developed to address stress corrosion
cracking (SCC) of turbine disk keyways and bores, the blade attachment regions (disk rim)
remain susceptible to SCC. Blade attachment designs are varied, and their geometrical shapes
complicate in-service inspection. Accurate knowledge of the attachment geometry is needed to
develop and apply reliable NDE, but this information is not always available.

5-27
The reliability of turbine disk blade attachments and the capability of in-service inspection
methods to detect and accurately characterize cracking have received considerable attention from
utilities. Although reliable NDE can be performed after blade removal, this approach is costly. It
has created a strong incentive to develop reliable methods that do not require blade removal.
The EPRI report Inspection of Turbine Disk Blade Attachment Guide, TR-104026-V1, [32] is
recommended as a reference document. It introduces the topic of attachment NDE and describes
conventional and advanced NDE methods and principles. It reviews the types of cracking and the
potential crack locations in both axial and circumferential entry blade attachment designs.
Current conventional NDE techniques and approaches are described including visual, liquid
penetrant, magnetic particle, eddy current, and ultrasonic inspection. Application principles and
inspection advantages and limitations are also presented.
The guide features ultrasonic inspection because, at present, it is the only method available that
is capable of examining the interior regions of the blade attachment. Complex design geometry
introduces many opportunities for false calls during ultrasonic inspection. Reflections from the
geometrical features of the various attachments can interfere with proper interpretation of
inspection results. The report discusses these effects and the difficult problem of determining the
geometry of blade attachments that is necessary for design and application of proper inspection
procedures. An ultrasonic technique for measuring attachment geometry is also presented.
EPRI report Steam Turbine Disk Blade Attachment Inspection Using Linear Phased Array
Ultrasonic Technology, 1000122, [33] is also recommended as a reference. It provides a brief
history of disk blade attachment inspection and the fundamental principles of ultrasonic linear
phased array technology. In 1997, EPRI developed a technique to inspect steam turbine disk
blade attachments using linear phased array technology. In 1998, a company to commercialize
the technology was sought to make the technique available to utilities with turbines that
incorporated the General Electric straddle-mount dovetail design. By the end of 1999, General
Electric had commercialized the technology, had refined the technique, and was offering it to
their utility customers. The cited report describes the development of the project as well as its
status up to November 1, 1999.
EPRI has developed a technique to inspect steam turbine disk blade attachments utilizing linear
phased array technology. The EPRI guide Field Application for Ultrasonic Linear Phased Array
Inspection of Straddle-Mount and Axial-Entry Disk Blade Attachments, 1000663, [34] provides a
brief history of disk blade attachment inspection and the fundamental principles of ultrasonic
linear phased array technology. It also describes the development of techniques for the inspection
of straddle-mount and axial-entry disk blade attachments using this technology.
The EPRI guide Ultrasonic Inspection of Steam Turbine Blade Roots, 1011680, [55] details the
research findings, transducer designs, application methodology, and observed detection and
sizing performance for the inspection of fir-tree root designs of large curved axial-entry
configurations. Axial-Entry Blade Attachment NDE Performance Demonstration, 1011677, [56]
consists of flaw detection and sizing performance of commercial inspection providers, using a
blind test approach similar to that being undertaken currently for straddle-mount blade
attachment designs. The final technical report provides test methodology and inspection
performance results and comparisons, including guidance for specifying inspection services.

5-28
5.8.7 Inspection of Nonmagnetic Generator Retaining Rings
Nonmagnetic retaining rings were introduced as an alternative to magnetic rings to minimize
heat losses and improve generator efficiency. The predominant alloy, 18% manganese and 5%
chromium (18-5), as well as other nonmagnetic alloys, were all found to be susceptible to SCC in
the presence of moisture. Although relatively few catastrophic failures of nonmagnetic retaining
rings have been reported, the economic consequences of a ring failure are too severe to ignore.
Early detection of SCC in nonmagnetic retaining rings by NDE can mitigate such a catastrophe.
NDE, however, has proven difficult because of the geometry of the ring and the method of
assembling the ring on the rotor.
The EPRI report Evaluation of Nonmagnetic Generator Retaining Rings, TR-104209, [35] is
recommended as a reference document. It provides a road map to help inspectors evaluate
approaches for the various inspection scenarios and detailed technical information for use in
developing an effective retaining ring inspection program. Investigation of NDE techniques for
retaining ring inspection revealed that no single inspection method or technique alone provides
the high reliability required for retaining ring inspection. High reliability can be achieved only by
implementing complementary methods or techniques to address the special considerations of a
retaining ring inspection. In addition to its assessment of state-of-the-art NDE techniques, this
investigation included an assessment of advanced techniques, resulting in recommendation of
several for inclusion in retaining ring inspection programs.
Retaining ring inspection requires considerable expertise to fully comprehend the capabilities
and limitations of the various techniques. Inspections must be tailored to address various
inspection situations including in-frame inspections, out-of-frame inspections with rings
installed, and out-of-frame inspections with rings removed.
Section 8.12 in Volume 2 of these guidelines contains a detailed procedure for removing,
inspecting, and reinstalling generator retaining rings. EPRI report TR-102949 gives detailed
methods to be used during operations, stand-by, and maintenance to keep generator retaining
rings free from exposure to moisture.
5.9 Inspection of Shrunk-On Components
When the turbine experiences any vibration or balance problem, the cause can sometimes be
related to the couplings. For this reason, a complete coupling inspection should be performed
when balance problems exist. Shrunk-on couplings are used on turbine and generator shafts
when it is not possible to use a solid coupling.
The checks used for solid couplings should be performed when inspecting shrunk-on couplings.
In addition to the solid coupling checks, there are special checks that should be performed when
inspecting a shrunk-on coupling. Normal coupling checks are listed in Table 5-6.

5-29
Table 5-6
Coupling Inspections Disassembly and Reassembly
After Disassembly
Normal Inspections Special Inspections
Coupling rim and face run-out Locking key tightness
Face flatness Bolt tightness on retainer plates
Visual inspection Secure staking of retainer bolts
Magnetic particle inspection Loose fits
Bolt elongation
Bolt and hardware damage Upon Reassembly
Locking plate damage Face flatness
Windage cover damage Rim and face run-out
Coupling spacer tightness Loose fits
Coupling spacer gear tightness Locking key tightness
Gear and spacer shifting Retainer plate bolt tightness
Bolt hole scoring or galling Secure staking of retainer plate bolts

Shrunk-on couplings should not be removed during normal maintenance. If the shrunk-on
coupling needs to be removed, the manufacturer should be contacted, and a representative should
be on-site to supervise the process. When a shrunk-on coupling is removed, the coupling should
be inspected for fretting, dimensional checks, key tightness, keyway damage, and galling or
scoring of any components. All retainer plate bolting should be inspected for damage. All bolting
and shrunk-on rings should be magnetic particle tested.
5.10 Bearings Journal and Thrust Types
Understanding bearing construction, operation, damage mechanisms, and operational indicators
will help the turbine engineer prepare and plan for outage contingencies. Because bearing repairs
are typically performed off-site, inspections to document the condition of the bearing and journal
should occur early in the outage cycle.
Four critical steps are involved in the bearing repair process:
1. Incoming inspection and removal of the old babbitt
2. Liner preparation to receive the new babbitt
3. Casting the babbitt
4. Restoring dimensional integrity and final inspection

5-30
Each phase of the repair process can affect the quality and serviceability of the repaired bearing.
Incomplete incoming inspections can cause delays in the final machining process. Improper
preparation of the liner and improper tinning can result in disbonding of the babbitt. Improperly
cast and cooled bearings can cause porosity, segregation, and disbonding. Improper preparation
and lack of fusion can cause separation and dislodging during a minor repair. Improper
machining can cause complete spin casting of the bearing again.
Journal bearings and thrust bearings are the two types of bearings generally found in turbine-
generators. Journal bearings confine the rotor in the radial direction, support the rotor weight,
and are usually located at the ends of each rotor. Some designs share a common bearing between
rotors. The term journal is associated with the area of the rotor that is encircled by the bearing.
While the journal bearing confines the rotor in the radial direction, it also allows the rotor to spin
safely at high speeds on a wedge of oil.
The bearing is lined with a soft material, usually tin-based babbitt. The babbitt can act as a
sacrificial material if the harder rotor comes into contact with the bearing surface, and it also can
absorb foreign particles too large to pass between the rotor journal and bearing babbitt without
causing significant damage to the journal surface.
Turbine-generator journal bearings are usually constructed in two halves that are split at the
horizontal centerline. The halves are bolted together and use dowel pins in the horizontal joint to
ensure alignment of the bearing halves.
Journal bearing construction designs are usually tilting pad or elliptical. Tilting pad designs use
either single or double tilting pads; the heaviest loaded pads are located in the bottom half of the
bearing.
The first step in forming the ellipse in an elliptical journal bearing is machining a cylindrical
bore through the bearing with shims in the horizontal split line. The elliptical form is obtained by
removing the shims when the bearing is assembled. The elliptical bearing has a primary loading
zone in the bottom half of the bearing and a secondary zone in the upper half. The elliptical
design with overshot grooves in the upper half passes more oil than a plain cylindrical bearing of
comparable size; therefore, it should have fewer heating problems than a plain cylindrical
bearing.
Some elliptical designs are reduced in width and are designated as shortened elliptical bearings.
Shown in Figure 5-3, elliptical and shortened elliptical bearings are a two-part construction. The
inner bearing component, also known as the liner, contains the babbitt on the inside diameter and
the outside is machined to a convex sphere also known as the ball. The outer component is the
ring, and its inside diameter is machined to a concave ball seat.

5-31

Figure 5-3
Elliptical Bearing Construction
Turbine and generator rotors sag from the rotor weight distributed between the bearings. The
ball seat allows alignment of the bearing assembly in the turbine pedestal to the sag geometry of
the rotor journal. In an unbolted state, the upper ring has ears with a clearance between the ears
and the horizontal split centerline of the bearing. After the bearing is aligned, the upper ring
hold-down bolts in the ears are tightened. The tightening of the upper ring pinches the liner so
that the bearing is locked in place. The amount of pinch is determined by the deflection of the
ears as the ring hold down bolts are tightened.
A thrust bearing absorbs and limits the axial movement or operating thrust of the rotor. The rotor
contains integral collars that restrain the rotor to the limits imposed on it by the thrust bearing
and the thrust bearing housing. Tilting pad and taper land thrust bearings are used in turbine /
generators. Tilting pads come in a number of designs, but usually rely on six pads, three within
each half of the bearing. The pads fit under lips machined in the bearing casing to prevent the
pads from moving in a radial direction. Locating pins through the bearing housing into the pads
prevent circumferential movement. To prevent seizing and to allow free tilting of the pads, the
protruding pins have a smaller diameter than the holes in the pads. The tilting of each pad takes
place between the back radius of the pads and the inner bore diameter of the casing in the region
of the pins on a line contact. By making the back radius of the pads smaller than that of the
housing produces the line contact. Tilting pads are self-aligning and therefore do not require
bearing casing adjustment features like a ball seat of an elliptical bearing. Lubricant is provided
to the bearing by flooding the bearing casing. Seal and drain orifices control lubricant flow out of
the casing. Higher bearing temperatures are found on tilting pad thrust bearings because:
Rotating journal forces oil away from the entrance spaces of the bearing
Constant churning of the oil in the flooded casing
Increased turbulence

5-32
Therefore, tilting pad thrust bearings have larger oil requirements and higher power losses. On
the positive side, tilting pad bearings are an effective corrective measure for shaft instabilities.
The increased bearing loads provide enhanced stability at light thrust bearing loads.
The tapered land thrust bearing is comprised of two stationary plates that react with two collars
on the rotor. The thrust plates are contained in a casing and are aligned to the rotating thrust
collars. The surface of the thrust plates is babbitted and contoured to assist in the formation of
the oil wedge between the rotating and stationary components. Oil is forced into the bearing and
radial feed grooves provided between each of the contoured surfaces allow oil to be fed both at
the base of the thrust plate and outwardly. The outer edge of the groove is damned to maintain a
positive pressure within the bearing. Orifices in the oil feed pipes control the amount of oil
entering each end of the bearing. The outer diameter of the assembly is spherically machined like
an elliptical bearing to allow the thrust bearing assembly to be aligned to the rotor thrust collars.
The thrust plates are pinned to the bearing assembly preventing rotation. Thrust transfer and
axial movement is restricted by a tongue and groove machined between the bearing assembly
and the standard.
Table 5-7 lists a number of bearing conditions and damage mechanisms that may be found
during an outage inspection.

5-33
Table 5-7
Recommended Action for Bearing Damage Typically Found at Inspection
Bearing
Condition
Outage
Activity
Remedial
Action
Possible
Consequence
Abrasion Depending on severity:
Hand scrape
Re-babbitt
Investigate lube oil and
remove the
contaminant and its
source.
Scored rotor journal
Corrosion Re-babbitt Investigate lube oil and
remove the
contaminant and its
source.
Corroded rotor journal
Disbonding UT inspection
Re-babbitt if unbonded
area exceeds
specifications
Investigate the previous
repair process.
Babbitt separation from
liner and bearing wipe
Hot bearing
Disbonding -
edge
PT inspection
Re-babbitt if unbonded
area exceeds
specifications
Investigate the previous
repair process.

Electrolysis Depending on severity:
Hand scrape
Minor repair
Re-babbitt
Investigate the current
source and inspect the
shaft grounding system.
Hot bearing
Excessive
clearance
Re-babbitt for elliptical
Measure and re-shim
for tilt pad
Re-babbitt if required
Bearing stability
Fatigue Depending on severity:
Minor repair
Re-babbitt
Lead
contamination
Re-babbitt Investigate the previous
repair process/vendor.
Wiping Depending on severity:
Hand scrape
Minor repair
Re-babbitt
Any one or more
combinations of the
above conditions
Hot bearing
Note: Any breakdown of the adhesion bond between the babbitt and the backing in the lower bearing half can begin to impact
heat transfer and subsequent cooling through the bearing.

5-34
Pre-outage preparations that can be completed in anticipation of outage repairs are listed in Table
5-8.
Table 5-8
Recommended Pre-Outage Preparations for Bearings
System Action
Journal bearing Repair procedure prepared, minor repair - local tungsten inert gas (TIG) repair,
major repair - re-babbitt, ball seat, qualified vendors selected, purchasing
documents and process ready
Tilt pad bearing Repair procedure prepared, minor repair - local TIG repair, major repair - re-
babbitt all pads, qualified vendors selected, replacement pads, replacement
hardware, purchasing documents and process ready
Journal repair Repair procedure prepared, qualified vendors selected, purchasing documents
and process ready
Thrust bearing Repair procedure prepared (if parts unavailable), major repair - re-babbitt,
qualified vendors selected, replacement parts, shims, thermocouples, thrust
plates, purchasing documents and process ready

Proximity probes and data collection support software are excellent diagnostic and preparation
tools. Unusual bearing conditions and circumstances can be red flagged before an outage,
giving an early warning for inspection and preparation. Existing bearing thermocouples can
provide limited information on a bearing condition. A bearing running hotter than normal may be
the result of an operational change or the result of in-service wiping of the bearing. Babbitt can
dislodge and limit journal movement within the bearing, causing increased loading and
temperature. Unexpected reduction in the temperature of a hot bearing may be the result of a
wipe or restriction clearing and the journal returning to normal position. A bearing improperly
installed during an outage may provide operational information before the telltale wear pattern in
the bearing is observed. Consequently, it is important for the turbine engineer to be aware of the
bearing operating conditions as a forecasting tool for outage planning and preparation.
5.11 Stationary Components
Figure 5-4 shows a typical diaphragm. The three major areas of a stationary system are listed in
Table 5-9.

5-35

Figure 5-4
Diaphragm Construction

Table 5-9
Separate Areas That Form a Stationary System
Steam Path Structure or Body Seals
Partitions Ring and its components Spill strips (removable, integral, insert)
Inner sidewall Web and its components Packing (addressed further in Section 5.13)
Outer sidewall
Each area is inspected during the outage to determine the exact repair scopes, but pre-outage
planning can be accomplished by understanding the repair histories for each stage, wear, and
damage mechanisms.
Before the outage, the following should take place:
The repair procedures are prepared.
Qualified vendors are selected.
Purchasing documents and process are ready.

5-36
Previous outage reports and repair recommendations should be the first in line of information
used to create the work scope for diaphragm and nozzle repairs. That information can be
confirmed or augmented by a review of each stage and the possible damage mechanisms
associated with the stage.
The following information is a review of damage mechanisms typically associated with
diaphragms and nozzles:
Solid particle erosion (SPE) is the result of very small particles having a very large economic
effect on repairs and loss of turbine efficiency. The source of solid particle erosion is
exfoliation of oxides from the inner surfaces of boiler tubes and steam piping. The oxide
grows as these systems operate at elevated temperatures and the exfoliation occurs during
lower loads. For a comprehensive study, see Reducing Solid Particle Erosion Damage in
Large Steam Turbines [36].
The particles are carried to the turbine and do damage when the right flow and particle size
distribution exists. The action is comparable to grit blasting the turbine components. The
damage is most severe in supercritical units. Both diaphragm pressure side and suction side
SPE can occur within the turbine. The primary effort to reduce the effects of SPE has been to
combat the effects of SPE by coatings, increased set back, and partition re-designs. Damage
from SPE tends to be limited to the HP section and first stages of the IP sections.
Water erosion caused by water droplets in the saturated steam is found in the wetter sections
of the LP turbines. Component joints that have leakage paths can be heavily damaged from
water erosion. Bucket tips, leading edges, and root trailing edges of the last stage buckets are
also areas where water erosion is prevalent.
Foreign object damage (FOD) results when foreign objects either left within the steam path
or introduced in the steam path come into contact with rotating and stationary components.
FOD can result from weld slag or a tool left within the turbine; even turbine components
themselves that come loose in service can cause dings, dents, and major damage. FOD can be
found in any stage.
Deposits in the steam path are caused from boiler carry over, water treatment chemicals, and
metals that can plate out on turbine buckets and diaphragm partitions. These deposits can
block discharge areas causing a reduction of stage efficiency or creating initiation sites for
corrosion damage. Stage conditions need to match the right steam conditions for the
deposition of material to occur. The main corrosion mechanisms occurring in a turbine are
corrosion fatigue (CF), stress corrosion cracking (SCC), and erosion-corrosion (EC). Pitting
(P) and CF of blades and SCC of discs tend to dominate as the costliest problems.
Corrosion in a turbine is complex and related to the environment including steam purity,
moisture evaporation, crevice concentrations, oxides, pH, velocity, turbulence, lay-up
duration and conditions, stress, stress concentrations and material properties. Metallic
deposits can accumulate in the HP section, but corrosion deposits and P, CF, and SCC tend to
occur in the latter stages of the LP section.

5-37
Cracking in the steam path is the start of breakage and the start of a component failure.
Location, service environment, service requirements, etc. are evaluated when crack
indications are found in steam path components. Run-repair-replace decisions for crack
indications can occur anywhere in the steam path. Each turbine section is significant because
of the potential problems that may result.
Component distortion is a common condition in the hotter turbine sections. Time,
temperature, and stress on the steam path components influence the amount of distortion.
Table 5-10 presents a matrix that provides a review of damage mechanisms and corresponding
planning options for each diaphragm area.
Table 5-10
Recommended Action for Diaphragm Damage Typically Found at Inspection
Location Item Discussion Planning
Rings or
webs
Centering pin
fits
Some damage should be expected.
Repair includes welding and refitting
for the clearance to the centering pin.
Include as a repair in the
diaphragm repair procedure.
Rings or
webs
Corrosion Usually occurs in the LP section.
Rings or
webs
Crush pins Some repair/fitting will be required
during outage, as a result of expected
wear or physical damage.
Fitting requires measuring the
corresponding location in the shell
and machining it to fit.
diaphragm repair procedure for
weld buildup
-or-
Repair information (material
identification and work package)
will be available for on-site utility
repair
Rings or
webs
Distortion -
dishing
HP and IP sections. This develops
over time and should be anticipated.
Include as a repair option in the
diaphragm repair procedure. It will
require repair and re-machining.
Rings or
webs
Distortion -
out of round
HP and IP sections. This develops
over time and should be anticipated.
diaphragm repair procedure. It will
require repair and re-machining
and may require replacement
packing.
Rings or
webs
Dowel pins There is a low probability of in-service
or disassembly damage.
The dowel pin requires removal if the
horizontal joint is repaired.
identification and work package)
are available for on-site utility
repair.
Rings or
webs
Hook fit -
packing
There is a low probability that a repair
will be required unless associated with
dishing or out of round condition.
Machine support is required after
repair buildup.
Include in the pre-outage,
development work package for
spill strip hook fit configurations.

5-38
Table 5-10 (cont.)
Structure Hook fit -
Spill strip
SPE damage usually occurs in HP
and IP sections.
Machine support is required after
repair buildup.
Pre-outage, development work
package for spill strip hook fit
configurations.
Rings or
webs
Horizontal
joint
Damage such as seal weld cracks,
erosion, damaged keyways, and
excessive opening can be anticipated.
Rings or
webs
Horizontal
joint bolts
Damage could possibly occur during
disassembly.
Mixed sizes are available as
spares.
Rings or
webs
Horizontal
joint keys
There is a high probability that higher
temperature/pressure stages will
require replacement.
This will require removal if the
identification and work package) is
available for on-site utility repair.
Rings or
webs
Horizontal
joint
miscellaneou
s hardware
There is a high probability that higher
temperature/pressure stages will
require replacement.
This will require removal if the
Rings or
webs
Horizontal
joint threaded
holes
Damage could possibly occur during
disassembly.
-or-
Rings or
webs
Steam seal
face and
inserts
Typical damage occurs from
excessive movement and SPE.
Significant damage may occur in the
HP section from fretting, galling, and
SPE.
Steam seal faces can be touched
up and hand dressed if the
damage is limited.
Rings or
webs
Support bars There is a low probability of in-service
mechanical damage, erosion, or
corrosion.
This may require disassembly for
diaphragm alignment.
Drilling and re-tapping if any work
is done to high temperature
diaphragms.
Replacement bars/shims should
be stocked or material and
machining process should be
available during an outage.

5-39
Table 5-10 (cont.)
Rings or
webs
Welds Although a low probability, some of
the original factory welds may become
distressed after time and require
repair.
Repair may require mechanical
securing and then welding.
The amount of weld deposited may
require stress relief.
Pre-outage activity may be limited
to understanding diaphragm
construction and an awareness of
repair options.
Seals Spill strips -
removable
There is a high probability that
replacements will be required for HP
and IP section diaphragms.
Damage includes erosion, corrosion
(LP section), cracks, and FOD.
Approximately 50% of the heat rate
loss associated with diaphragms is
spill strip leakage losses.
A replacement can usually be
ordered and received during an
outage.
This requires early identification
and correct part identification.
integral
Located in the HP and IP sections.
Damage of these strips includes
erosion, cracks, and FOD.
Since this repair requires weld
buildup and machining, early
outage identification is helpful.
Pre-outage planning includes work
package development.
insert
Located in the HP and IP sections.
Damage of these strips includes
erosion, cracks, and FOD.
Since this repair requires weld
buildup and machining, early
outage identification is helpful.
Pre-outage planning includes work
package development and part
resource identification.
Steam
path
Partition &
sidewall -
damage
Surface damage includes: FOD, DPE,
thinning (erosion), corrosion, and
general in-service partition damage
Generally, SPE occurs in HP and IP
sections, and water erosion occurs in
the LP section.
Approximately one-third of heat rate
loss associated with diaphragms is
due to the surface condition of the
partition.
Trailing edge cracks are caused by
differential cooling between heavier
and thinner sections.
Fillet welds are structural in nature
and weld cracks may result from
differential thermal stress.
Include in the repair procedure.
The general planning work scope
should come from previous outage
reports and recommendations.
Pre-outage preparation should
include compilation of diaphragm
partition and machining
dimensions. Plans to obtain data
during the outage should be
considered if the information is not
available.

5-40
Table 5-10 (cont.)
Steam
path
Partial
partitions at
joints
The pins supporting these partial
partitions may be damaged with the
same mechanisms as full partitions.
Steam
path
Bridges Bridges are structural in nature.
Cracks and physical damage are
typical discrepancies found.

5.12 Buckets/Blades
Turbine buckets/blades are comprised of three basic sections: attachment, vane, and tip area (to
include the bucket/blade area). The attachment of the buckets/blades to the rotor may be the
same design and size for any number of stages on a rotor. The method in which the final
bucket/blade is attached to close or complete a row may vary.
The vane section and the tip configuration may be the distinguishing difference between rows of
buckets/blades on a rotor. Vane sections are a combination of impulse and reaction designs. Most
vane designs will differ from stage to stage restricting the interchangeability of stage from one
turbine to another. An exception may be the L-0 and L-1 rows.
Turbine stages are normally numbered with the first stage starting as the steam enters the turbine
and continues in sequence until the last stage and steam exiting the turbine. An alternate method
of identification usually used in the LP section of the turbine is to begin with the last row of
buckets/blades and identify it as either the L stage or L-0 stage, and then identify each
preceding row in reference to the last stage. The next-to-last stage becomes L-1, then L-2,
and so on as the reference moves against the steam flow.
This is a useful convention because the L-0 and L-1 groupings share the same respective designs,
operating conditions, and problems. Although turbines vary in number of stages, they can readily
be identified and grouped according to last stage designation.
Previous outage reports and repair recommendations are the first place to look for an outage
action plan for bucket/blade replacements. External inspection access locations may also provide
condition information before major outages. Understanding steam path damage mechanisms and
having replacement component design information available prior to the outage should provide
an edge against outage delays if the unexpected inspection finding occurs. Manufacturing of the
buckets/blades would still be required if an outage inspection finding dictated replacements.
It may not be practical to have design information created for all stages, but instead, a
combination of complete design for priority stages, attachment details for shared attachments,
and bucket cover and tip information will all help reduce the time required during an outage to
make decisions and obtain replacements. Understanding bucket damage mechanisms and

5-41
sensitive stages will help in assessing which stages should have a design pool of information
available. The following is a brief review of damage mechanisms typically associated with
buckets/blades.
Fatigue is widely classified as either high cycle or low cycle. High-cycle fatigue is associated
with a high local stress in a moderate dynamic stress. Initiation may take a long time, but time to
failure may be short after a crack begins. Growth may stop and restart as the dynamic stimulus is
removed. Such intermittence may be the result of changes in operating conditions such as
excessive condenser back pressure or partial arc operation.
Low-cycle fatigue is associated with fewer cycles to failure and higher alternating strain ranges.
Fewer cycles are required to initiate a crack and fewer cycles to propagate a crack than in high-
cycle fatigue. Often, fatigue is associated with some other initiating mechanism to create the
stress riser. Stress concentrations may be formed as a result of:
A geometrical change in the original design
Created during the manufacturing process
A maintenance process
A heating or cooling process either during operation (for example, a rub) or repair
A chemical attack such as pitting
Corrosion-assisted bucket/blade failures typically occur in the attachment area, but they are not
limited to the attachment. Observing deposit buildup patterns before a rotor is grit blasted helps
to identify possible locations of corrosion-assisted problems. Corrosion-assisted failures can also
occur in cover/shroud areas, tie wire, or dampening attachment areas; anywhere that deposit
buildup can occur. The presence of a corrosive environment can affect the materials fatigue
strength and, therefore, degrade the ability of the component to withstand the steady and
dynamic stresses imposed on it. The bucket/blade and rotor material endurance limit can be
significantly affected when a rotor is out of the turbine during an outage. Rotors left unprotected
in moist outdoor environments can have local area corrosion accelerated.
Physical damage to the exposed area of the bucket assembly occurs from three primary
mechanisms:
Erosion. Erosion within the steam path typically will take two forms: solid particle erosion
(SPE) and water erosion. SPE damage is associated with the HP and IP section, and water
erosion takes place on the outer-half leading edges of later LP stages. Covers and tenons are
susceptible to both types of erosion. A general thinning of the vane section can also occur.
SPE and water erosion tend to remove gross quantities of material and have very noticeable
results; thinning is a gradual loss of material and is noticeable at the trailing edges.
Foreign object damage. Foreign object damage (FOD) is akin to erosion damage in that the
rotating element is striking objects. The difference is the size of the objects. FOD damage
can occur quickly and severely.
Rubs. Rubs occur in a radial or axial direction. Radial rubs can smear tenon and cover
material or groove the root area of the bucket from the root spill strip. Axial rubs can also
damage covers and root areas of the buckets.

5-42
Table 5-11 associates typical damage mechanisms to turbine sections.
Table 5-11
Blade Damage Typically Found at Inspection
Type Attachment Vane Tip Area
Fatigue -
cracks
Notch keys
Dovetail pins
Trailing edges
Tie wire holes
Cover lifting
Covers
predominately axial
toward tenon
LCF Notch area lifting
HCF Notch area lifting
Root radii
Tie wire holes
Creep High temp. stages
Corrosion
Pitting Especially L-2 through
L-0
Especially L-2
through L-0

SCC Especially L-1 Especially L-1
Physical
SPE HP & IP sections Tenons HP & IP
Sections
Water erosion L-1 through L-0
Leading edge
Outer radius
L-3 through L-0
Covers
Tenons
L-0
Trailing edge
Inner radius

Thinning
FOD Anywhere along vane
section
Cover & tenon
Rub Predominately radial.
Concern if severe on:
First HP & IP stages
Last LP stages
Evaluate axial
Predominately radial.
Concern if severe on:
First HP & IP stages
Last LP stages
Evaluate axial
Other Fretting

EPRI report State-of-the-Art Weld Repair Technology for Rotating Components: Volume 2:
Repair of Steam Turbine Blading, TR-107021-V2, provides weld repair details for turbine
blading airfoils, erosion shields, tenons, and cover bands.
Volume 2 of these guidelines, in Sections 5.2 and 5.3, also provides detailed procedures for
blading tenon, tie-wire hole, and erosion shield repairs.

5-43
5.13 Rotors
5.13.1 Causes of Rotor Bowing
First on the rotor problem list is rotor bowing. The following are causes for rotor bowing and are
listed from the most common to the least common.
1. Severe rubbing
2. Water induction
3. Metallurgical
Non-uniform material properties
Non-uniform residual stresses
5.13.1.1 Severe Rubbing
Rotor bowing caused by rubbing is a result of non-uniform local yielding and residual stresses.
Rubbing occurs when the rotor body comes in contact with a stationary component such as oil
deflectors, interstage packing, or end packing. The rub is usually a secondary effect of some
other machine condition such as overly tight clearances or excessive vibration of the system.
Rubs are usually transient in nature. For example, a rub on the interstage packing may eventually
remove enough material to become a lighter rub and eventually eliminate itself.
Rubs can be in either the radial or axial direction. A full annular type of rub would occur when
the rotor is in continual contact with a stationary component. A partial contact rub is the more
common of the two and can be either a single-point rub with the stationary component or a
multi-point rub where contact is at multiple locations
When the rub is a combination of impact and rubbing friction on the stationary component, the
impact usually creates a secondary effect in the form of a rebounding motion. This type of rub
will cause circumferential temperature gradients from the friction that is created and is usually
more severe on one side of the rotor. If the rotor bows, it will do so gradually toward the rub or
high spot. This is as a result of the fact that the hot area expands and yields in compression,
which causes the rotor to bow toward the rub.
A simplified sketch of the orbital motion of a rotor is shown in Figure 5-5 [37]. Note that the
high spot always faces out. The high spot comes in contact with the stationary component,
causing the rub.

5-44

Figure 5-5
Mechanics Describing Rubbing Process
The following is the sequence of a rub at constant rotational speed below the rotor first resonance
speed:
1. Due to the rub, the shaft bows in the direction of the high spot and a new unbalance force
occurs.
2. The original and rub-related unbalances add together, producing an effective unbalance
force.
3. At a constant rotational speed, the phase lag between the effective force and response (high
spot) is constant. This means the shaft has to rotate, yielding a new high spot. The magnitude
of the rotor orbit also increases as the center of mass moves away from the center of rotation.
This causes greater unbalance, causing the rotor to rub harder.

5-45
Severe vibration effects may occur during constant speed while the rotor is operated close to or
below its first critical speed. Some turbines use vibration detection equipment where the
response of the pickup falls off rapidly below 800 rpm and is virtually ineffective below 500
rpm. Therefore, it is difficult to detect potentially destructive levels of self-accelerating vibration
from rubbing below 800 rpm when the vibration equipment detection capability is limited.
Operation at a constant speed below the vibration equipment detection level should be avoided.
Vibration levels for slow-speed balanced modern HP and IP rotors at 1000 rpm should be nearly
zero. A 5 mil (0.127 mm) vibration should be unusually high for those rotors at 1000 rpm and
may be indicative of a rub. Two conclusions result from the above:
Operating turbine rotors at a constant speed below vibration equipment detection levels
should be avoided.
Unusual vibration at slow speeds may indicate packing rubs, and the turbine should be
returned to turning gear to straighten out the rotor. The rotor should not be operated at low
speed to clear the rub.
Rubs occurring above the first critical speed will cause the center of mass to move toward the
center of rotation and decrease the magnitude of unbalance. Very hard rubs above the first
critical speed are required to excite the rotor. The effects of in-service rubs are reduced if the unit
is operating at high load and high steam flow; the steam flow tends to cool the hot spot, reducing
its effect.
Having pushed through a rub to above the first critical speed is not insurance that the rub has
cleared; it will probably be experienced again on a future coast-down. In most cases, the
machining action of a rub will eventually provide the increased clearance for smooth operation.
The exception to increasing clearances by rubbing is associated with non-metallic materials such
as textolite and some packing designs that use a slant-tooth design. Slant-tooth design uses a
different material, tends to flex out of the way instead of rub away, and increases its cross-
section as it is rubbed.
The consequences of increasing clearances by rubbing are:
Reducing sealing efficiency at the rub location
Damage to the stationary component
Damage to the rotating component
It is important to minimize rotor deflections during the rubbing process to minimize the
clearance increase caused by rubbing. The efficiency of the seal will be reduced because of the
damage to the sealing profile, but reducing the amount of clearance opening can minimize the
consequences. Several seal designs are currently available to withstand the effects of rotor
deflections during operation.
The rotor maintains a permanent bow if the overheating caused by the rub is severe enough that
sufficient area is heated that has expanded and yields in compression. This helps move the rotor
toward the rub. Then, as the rotor normalizes in temperature, the material in tension tends to bow
the rotor in the opposite direction.

5-46
5.13.1.2 Bows Caused by Water Induction
Rotor bows caused by water induction result from a hot rotor being quenched so that it yields in
tension, thereby causing the rotor to bow away from the cooled spot. As the rotor normalizes in
temperature, the yielded material tends to bow the rotor in the opposite direction. Water
induction into a turbine section can also cause distortion of shells, which hump into the rotor
causing severe rubs.
5.13.1.3 Bows Caused by Metallurgical Problems
The least common cause of bowing is from metallurgical problems in the rotors. The cases are
few but documented. Metallurgical bows are not well understood, but they are usually associated
with high-temperature rotors and may be the result of non-uniform yield strength and material
creep properties. Turbine manufacturers changed the heat treatment requirements for turbine
rotor forgings in the early 1960s to control impurities and provide more uniform material
properties. The progression of the bow is slow and, therefore, corrective action can easily be
planned.
5.13.1.4 Corrective Actions
The following actions are available for bowed rotors:
Balance to offset unbalance
Straighten mechanically or thermally
Heat lathe to straighten
Re-machine new compromised center of mass
Rotor run outs should be taken at each outage inspection on high-temperature rotors. Historical
readings will help to plot any rotor bow and predict a growth rate. Run-outs should be taken
early in the outage to provide a warning for any unexpected condition. In-service balancing
information will also provide a warning of any changing condition.
Requirements for in-service mid-span or static balance shots may be indicative of an increasing
rotor bow. Rotors are manufactured to a run-out tolerance of one mil (0.0254 mm). Anything in
the field that is 3 mils (0.0762 mm) TIR or less is considered acceptable and is only slightly
bowed. Rotors with 67 mils (0.1520.177 mm) TIR of bowing (between bearings) are
considered to have a minor bow that should be correctable with slow-speed balancing. Rotors
with 10 mil (0.254 mm) TIR or greater are considered severely bowed, and corrective action
should be applied.
The corrective action for a severely bowed rotor may be a combination of heat lathe
straightening and machining. The heat lathe may remove a portion of the run-out ranging from
25% to 33%. The heat lathe also reduces residual stresses created during the bowing process.

5-47
A machining plan is developed after taking a comprehensive set of run-out readings. A new
center is determined for the rotor. New diaphragm packing, end packing, coupling bolting, and
resized journal bearings are the typical components required to install a re-machined rotor.
5.13.2 Other External Rotor Problems
Other types of external rotor problems include:
Seal area damage associated with rotor rubbing
Corrosion - seal areas/rotor body, especially the LP/bucket/blade attachments
Attachment creep in high-temperature rotors
Journal scoring
Oil deflector area scoring
Coupling bolt hole damage
Except for the possibly of journal damage, the external rotor damage would be determined
during an outage. Damage and its extent are determined by visual inspection, NDE replication,
MT, and UT during the outage. UT can be used to inspect rotor areas that are not available to
direct sight inspection, such as the rotor dovetail with the bucket/blade installed. The type of
repair needed would normally be machining of the damaged area and redesigning the
corresponding component. An extreme repair would include a weld repair for the damaged area.
Possible rotor body problems include cracks. Rotor cracks have been detected by using a
vibration detection system that uses proximity probes. The information provided by the
proximity probes, displayed in cascade, polar, 2X amplitude phase time (APHT) plots, and 2X
orbits associated with APHT plots, are used to evaluate the rotor condition. The frequency of in-
service rotor cracking is increasing because rotors are running longer between inspections and
more units are being called upon for peaking duty.
A transverse crack occurs most frequently with a slight variation of a cup shape occurring under
a shrink fit and has the appearance of a tension fracture in ductile material. Torsional cracks
appear less frequently than transverse cracks and are readily identifiable. Longitudinal and
transverse symmetrical cracks are rare. The following are a few things to remember about
cracked shaft detection:
A cracked shaft is a bowed shaft.
A rotor system with an asymmetric shaft and a radial side-load force rotating at a speed near
half of any resonant frequency may experience high 2X vibration amplitude and 2X phase
shift.
In roughly 75% of the cases, the 2X component does not occur at operating speed.
Taking torsional coupled with lateral vibration measurements will assist in vibration analysis for
rotor crack detection.

5-48
As a result of two generator shaft cracking events experienced at a large nuclear generating
station in 2004, EPRI produced a technical report containing a tutorial on the subject. Generator
Rotor Shaft Cracking Management Guide, 1011679, [61] includes a discussion of turbine-
generator shaft torsional dynamic behavior, sources of excitation from the generator or grid,
locations of damage and mechanism involved, viability of ultrasonic testing for shafts with
shrunk-on couplings, effects of unit uprates, and monitoring schemes.
5.14 Shaft Seals
Typical damage that occurs to steam deflectors, interstage (diaphragm) packing, and shaft
packing during operation is the following:
Erosion solid particle and water
Corrosion chemical attack
Cracks brittle
FOD
Electrolysis
Abrasion
A rub is the other damage that occurs to the rotor body shaft and diaphragm packing in addition
to the above list. Since spill strip clearances are greater than rotor body sealing clearances, they
do not normally rub. The predominant wear for spill strips is erosion. Each packing strip and
each spill strip have a spring pushing on them to keep them in their smallest diameter position.
These springs are inspected for freedom of movement and cracking when the sealing component
is inspected.
Unlike turbine seals, modern generator hydrogen seals made with steel backing and babbitted
seal surfaces are designed to float. The seal moves freely with the rotating shaft radially but is
restrained from rotating with the shaft. The hydrogen seal is made of two sealing rings. Oil is
forced between the outer ring (air side) and the inner ring (gas side) at a pressure (typically 4.5
psi [31 kPa]) greater than the generator hydrogen pressure. Oil flows between the constricted
space between the seal and the rotor, preventing hydrogen gas from leaking along the rotor.
Smaller clearances are found in the hydrogen seals than in any other rotating sealing areas within
the turbine-generator. If, for some reason, the rings are prevented from floating, damage to the
hydrogen seal can occur by:
Contact between the shaft and the seal
FOD or particles entrained in the oil trying to pass between the tighter clearances
Electrolysis
An offset seal will cause burning or varnishing from heat buildup and insufficient oil flow to
cool the seal. Damage to the hydrogen seal will reduce sealing capability and cause hydrogen
consumption to increase.

5-49
Some seals or deflectors are assembled to compensate for rotor sag. The seals or deflectors are
assembled with equal clearance on each side, but biased to the vertical clearances. The top
usually has two-thirds of the clearance, and the bottom portion has one-third of the clearance.
For example, if the total seal clearance is 30 mils (0.76 mm):
Each side is set at 15 mils (0.381 mm) clearance.
The top clearance is set at 20 mils (0.51 mm).
The bottom clearance set at 10 mils (0.25 mm) clearance.
Contact and damage to these seals or deflectors can occur if they are not assembled properly.
Table 5-12 lists typical design clearances for sealing areas. The listed operating clearance is
based on experience and falls on the outer tolerance edge of the design clearance. Maintaining
design clearances requires that a machine be aligned within tolerances, but this does not account
for the operating variables that can increase the sealing clearances.
Table 5-12
Typical Seal Design Clearances with Field Tolerances
Seal Design Clearance Field Tolerance Operating
Clearance
Spill strip See the clearance diagram provided
by the OEM.
15 mils
( 0.381 mm)

Root radial See the clearance diagram provided
by the OEM.
10 mils
(0.254 mm)

Root axial See the clearance diagram provided
by the OEM.
10 mils
(0.254 mm)

Diaphragm packing 15 mils (0.381 mm) +10 to -5 mils
(+0.254-0.127 mm)
25 mils
(0.635 mm)
Steam packing 15 mils (0.381 mm) +10 to -5 mils
(+0.254-0.127 mm)
25 mils
(0.635 mm)
Hydrogen seals
3600 rpm,
babbitted steel
10 mils [< 20 ] (0.25mm) 1 mil
( 0.025 mm)
1015 mils
(0.25-0.38 mm)
Hydrogen seals
3600 rpm,
babbitted steel
12 mils [20 ] (0.30mm) 1 mil
( 0.025 mm)
1520 mils
(0.38-0.51 mm)
Hydrogen seals
1800 rpm,
babbitted steel
10 mils (0.25 mm) 1 mil
( 0.025 mm)
20 mils (max)
(0.51 mm max)
Hydrogen seals
3600 rpm, bronze
8 mils (0.20 mm) +1 0 mils
(+0.025 0 mm)

Hydrogen seals
1800 rpm, bronze
3.5 mils (0.09 mm)

5-50
Table 5-12 (cont.)
Typical Seal Design Clearances with Field Tolerances
Seal Design Clearance Field Tolerance Operating
Clearance
Air deflectors
aluminum
Alterrex
50 mils (1.27 mm) +25 0 mils
(+0.64 0 mm)

Oil deflectors
1800/3600 rpm
20 mils [8-15 ] (0.51 mm) +5 0 mils
(+0.13 0 mm)
2 mils/inch
(0.02 mm/cm)
Oil deflectors
1800/3600 rpm
30 mils [15-21 ] (0.76 mm) +5 0 mils
(+0.13 0 mm)
2 mils/inch
(0.02 mm/cm)
Oil deflectors
1800/3600 rpm
40 mils [21-31 ] (1.02 mm) +5 0 mils
(+0.13 0 mm)
2 mils/inch
(0.02 mm/cm)
Oil deflectors
1800/3600 rpm
50 mils [31-40 ] (1.27 mm) +5 0 mils
(+0.13 0mm)
2 mils/inch
(0.02 mm/cm)
Oil deflectors
Textolite
exciter
25 mils (0.64 mm) +5 0 mils
(+0.13 0mm)

Oil deflectors
aluminum
exciter
15 mils (.38mm) +5 0 mils
(+0.13 0mm)

From experience, nominal clearance may be as high as 2 mils per foot (0.0508 mm per 30.48 cm)
of rotor span between bearings. This value has been observed from many inspections and is an
average row clearance after normal operation. A clearance of 34 mils (0.8636 mm) can be
expected for a rotor with 17' (5.18 m) between bearing spans.
Packing and spill strips are inspected for radial rubs. The corresponding rotor, bucket, and cover
areas should also be inspected for severity of rub. Sharp edges and deep grooves should be
addressed and blended. Some spill strip rubs are the result of a corner lifting on a bucket cover.
The following is a list of conditions that might be found regarding rubs:
A consistent rub around the circumference of the rotor may indicate tight clearances or that
the rotor was bowed during operation.
The diaphragm may be out of round if sealing teeth are rubbed on the top and bottom.
Alignment may be the issue if the teeth are rubbed only on the top or bottom. It may be
general alignment; it may be a single diaphragm out of alignment. It may be necessary to
perform a tops-on/tops-off alignment procedure.
Rubbing only on the bottom of the rotor may indicate shell humping from water induction.

5-51
Axial ledges on wheels and bucket cover edges should be carefully inspected for axial rubs. The
corresponding areas of the diaphragms should be inspected. The damaged area may require
either hand blending or re-machining, depending on the severity of the rub.
The high-low labyrinth teeth of packing and the corresponding rotor location should be inspected
for axial rubs. Incorrect packing may be the cause of a single location rub or differential thermal
growth. The repair may require re-machining a new labyrinth sealing area.
New designs are available to increase both the sealing efficiency and the longevity of the seals.
Packing is designed and in service that at no and low loads retracts from the sealing position and
provides an addition clearance of approximately 60 mils (1.52 mm). The additional clearance is a
benefit during startup when rotor vibrations may be excessive, which may be the case during a
startup after an outage. The first roll or two may have higher than desirable vibration levels until
the rotor is balanced for operation.
EPRI report Evaluation of Replacement Interstage Seals for Turbine Upgrades, 1010214, [57]
evaluates the typical economic benefits of improved interstage packing, identifies the various
seal and packing design alternatives available, describes their functionality, and describes any
O&M issues that have been observed in their use.
Evaluation Tool for Cost Effective Steampath Upgrades, 1004565, [58] provides engineers with
a basic understanding of the underlying principles of the new advanced designs of replacement
steam path components and analysis tools for large turbines. The report will also include
guidance on the relative value of various new design features on the overall improvement. The
unique design issues associated with fossil and nuclear turbine performance will also be covered,
as well as the overall plant cycle issues that are involved in upgrade or uprate decisions.
5.15 Valves
5.15.1 Stop Valves
The stop valve primary function is to provide a second line of defense against energy from the
boiler failure in the event of a control valve failure. The main stop valve also closes as a routine
activity when the turbine is tripped. Some stop valve designs also incorporate a bypass valve that
is used as low load control valve. The components that make up typical stop valves are:
Lid
Disk assembly cap/bypass valve/disk
Seat
Pressure seal head assembly pressure seal head/bushings/valve stem
Steam strainer
Valve actuator hydraulic components

5-52
Typical maintenance for stop valves addresses the wear areas of the valve. The primary wear
areas of the stop valve assembly for high-pressure turbines are the bypass valve and the disk
assembly. The primary wear mechanism is SPE, but water during startup can also do significant
damage. Water can accumulate and erode the valve components if the drains that are
incorporated in the valves are not functioning before and during startup. The bypass valves are
used for full-arc admission during turbine starting. Bypass valves come in a variety of designs
and configurations; they can be coated or uncoated; skirted or unskirted; solid stellite, overlay
stellite, or no stellite. Upgrades for bypass valves and stems are provided to combat the effects of
SPE. The upgrades include redesign of components, diffusion coatings, overlay coatings,
material changes, etc. Other potential valve internal wear areas include stem bushings, disks, and
seats.
Intervals, methods, and details for the valve body (casing) internal inspections are typically
recommended by the original equipment manufacturer. The typical internal areas to be inspected
after grit blasting are:
Intersections valve inlet/outlet/equalizer
Connections valve body/stop valve seat ledge region
Stop valve dam-to-casing welds
Internal inspections look for the effects of age and operation, typically displayed as cracks. Some
components may need to be modified as operational changes take place (base load to cycling).
Some of the internal areas that may require modification are sharp radius interfaces such as the
steps in diameters of the lid.
External connections of main stem piping should also be included in a comprehensive inspection
program. The effects of age, operating temperature, local stresses and operating practices in the
right combinations will be reflected as some level of creep damage. It is important to pay
appropriate attention to valve casing inspections especially as units extend the intervals between
major outage periods. Pre-outage planning should incorporate some level of preparation for
crack indications from the outage inspection. The planning could include gathering and
collecting the necessary information if a weld repair would be required for a main steam
attachment weld.
Condition Assessment Technology for Steam Valves, 1010211, [59] is a generic guide that
describes methods and procedures for valve disassembly, assessment of condition and wear, and
proper reassembly for long-term operation. The guide contains specific procedures for 12
commonly used steam valves in full-speed and half-speed turbines.
5.15.2 Control Valves
Control valves provide the first line of defense against turbine overspeed during emergency
conditions. The control valves control turbine speed and load by increasing or decreasing steam
flow into the HP turbine. A typical control valve consists of:
Stand assembly stand/bushings/valve stem/disk

5-53
Seat seat stellite/seat pins
Valve actuator linkage/hydraulic components
Control valves are exercised continuously during operation; therefore, the greatest wear area is
bushings. Bushings support and restrain the valve stem and are also found in each interface of
the operating linkage. Control valves require the same internal and external inspection as stop
valves, but in addition, the control valve seat stellite inlay and seat pin welds need to be
inspected. The critical external weld inspection area is the weld to the main steam leads if the
valves are separately mounted.
Control valve condition assessment is covered in EPRI report 1010211 mentioned in the
previous section.
5.15.3 Reheat Stop Valves
The reheat stop valve (RHSV) is similar in maintenance activities to stop valves and serves
similar functions. The RHSV provides emergency protection as the second line of defense
against turbine overspeed from stored energy in the reheater. The intercept valve (IV) is the first
defense. Control circuitry provides trip anticipation and valve actuation for the IV. Normal
operation of both valves is wide open. Reheat valves can be either separate or combined into one
valve called a combined reheat valve (CRV).
Reheat stop valve condition assessment is covered in EPRI report 1010211 mentioned in the
previous section.
5.15.4 Non-Return Valves
The non-return valves (NRV) are located in the turbine steam extraction system. The turbine
extractions provide steam to the unit condensate and feedwater heater systems. The available
energy stored in the extraction piping and heaters is often sufficient to significantly contribute to
turbine rotating speed during a turbine trip.
The NRVs are comparable to a free swing or a power-assisted check valve. In acting as a free
swing check valve, the flapper or disk allows flow to enter and freely move through the valve.
The disk pivots downward as flow diminishes. The disk will seat if flow is stopped or if a flow
reversal occurs. The power assistance is used for valve closure, and it causes the valve to close
before flow reversal occurs.
An NRV may be equipped with a single-acting spring to close the cylinder connected to the
swing arm. Upon loss of signal or a turbine trip, air is removed from the cylinder, allowing the
spring to close the valve at low flow and before reversal of flow. The NRV prevents a flow of
steam to the turbine that would either cause or contribute to a turbines overspeed.
The typical NRV shown in Figure 5-6 is not designed to handle reverse water flow, but it may be
called upon to act as a line of defense against water induction, even though valve design does not
guarantee tight closure.

5-54

Figure 5-6
Typical Non-Return Valve Construction
Typical maintenance requirements for this type of NRV address the following wear areas:
Bushings for the swing arm shaft
Swing arm shaft
Disk and post assembly
Seat
Seals-double bearing covers-not external closure assistance/soft packing/mechanical seal
Operating cylinder
Seat and disk closure condition is important to the operation of the valve. Outage inspections
typically reveal some amount of seat damage from disk closure impact or FOD. Often, the
damage can be lapped out easily. Other times, either repair to the inlay or replacement of the
valve is required. Seat inlays are usually made from stainless steel or a hard-face material like
stellite. Sealing condition checks can be performed during non-major outage periods. By
removing the lid during non-major outage periods, a visual internal inspection and a tissue paper
test between the disk and seat can be performed, providing valve condition and sealing
information.
5.16 Casings, Steam Chests, and Nozzle Chests
The pressure-containing components of turbine sections are comprised of:
Outer shells
Inner shells
Casings
Exhaust hoods
Nozzle boxes

5-55
The high-pressure section is comprised of thick-walled, high-quality alloy castings. The
intermediate- and low-pressure sections may be made from castings of thinner section thickness,
fabrications of welded construction, or combinations of both. The higher temperature materials
will generally be a variation of 1.5% chromium, 1% molybdenum, and similar to ASTM
standard materials for the same temperature and pressure service. Lower temperature materials
may be cast steel or cast iron. Temperature, pressure, and service are considerations for the
material selection. Repair welding can generally be done on steel and alloy castings. The
appropriate weld procedure, consideration of component geometry, and thermal expansion are
essential for serviceable repairs.
Multiple shell construction is used as pressure boundaries, diaphragm carriers, and extraction
locations between turbine stages. Unit construction and operation induces stress in the
components as they are heated and cooled to meet operating conditions. The internal areas
respond quicker than the external areas. The turbine rotor responds thermally much quicker than
shells and if not warmed or cooled uniformly with the shells may cause axial rubs.
The lower temperature section is not as susceptible to temperature stresses as the higher
temperature section. Lower temperature sections are relatively lighter in construction and more
flexible. However, thermal cycling of a unit has an impact on all the sections. The typical
maintenance concerns of turbine casings from operation are:
Distortion
Cracking
Erosion
Galling
Casing distortion is a common problem associated with service at elevated temperatures. The
most common form of distortion is clam shelling or smiling. The horizontal joint is open
toward the center of the section and closed at the outer edges when viewed along the axis of the
machine. Another form of distortion is humping, where the horizontal joint is open on the
ends, closed in the center at the outer flange, and open in the center of the inner flange.
Shell distortion is often linked to water induction incidents. The effects of distortion range from a
nuisance to disassembly/reassembly problems. Efforts may be made for thermally relieving some
of the stresses or re-machining the shell. Planning preparation including resource identification
and repair options can be evaluated as preparation for an outage if a section has experienced a
water induction incident.
Most cracking in high-temperature shells is a result of thermal stresses where stress
concentrations, section changes, etc., respond to differential heating and cooling, causing high
stresses. A typical repair for cracks is to grind out and blend them. Severe cracks require
stitching, weld repair, or other action to restore the integrity of the shell. Shell geometry should
be reviewed to reduce stress concentrations as preparation for increased cycling duty. Low-
pressure and temperature sections also experience increased cracking from operational changes.
Fabricated sections should also be reviewed for stress risers and pre-outage planning
accomplished to address repairs and preventive measures.

5-56
Solid particle erosion occurs in higher pressure and temperature sections while water or steam
erosion occurs in lower pressure and temperature sections. Welding and machining in higher
temperature sections typically repair the erosion damage. Ductile filler materials are typically
chosen for repair. Low-pressure and low-temperature sections can be repaired with material
replacement products that can be cast. Pre-outage planning would include identifying resources
and materials for repairs.
Component assembly face galling may be the result of distortion, oxide buildup, tight clearances,
or interference fits. Repair is typically cleaning and removing the torn material but weld repair
and re-machining may be appropriate.
Other problems that may be encountered while doing shell inspections are:
Casting defects
Welding defects
Fabrication defects
Each defect should be evaluated for its impact on the serviceability of the component. Not all
defects are harmless and not all are serious. An attempted repair may increase the scope of work
without increasing the serviceability of the component. Therefore, considerations should be
given to:
The cause of the indication
The stresses in the area
Probability of propagation
History of the section and indication
Possible operation changes that might impact the indication
A brief list of things to consider when reviewing the need for a casing repair is provided in Table
5-13.
Table 5-13
Casing Repair Issues
Item Relevant Factors
Base Material Composition, weld ability, wall thickness, minimum wall to retain pressure,
allowable stress at temperature, operating stresses
Indication: General Location (surface, subsurface, proximity changes), geometric, thermal,
pressure
Indication: Weld Geometry, depth, extent, orientation, type
Crack Pinhole, casting flaw
History NDE (methods, results), repairs, operating conditions, operation pattern
Repair Options Mechanical, welding

5-57
5.17 Generator
5.17.1 Classifications
Generators are classified not only by their capability but also by their speed (number of poles),
type of cooling, number of coolers, type of coolant, coolant flow path, retaining ring attachment,
and type of frame construction. Table 5-14 presents examples of combinations of cooling design
and retaining rings:
Table 5-14
Combined Cooling Designs with Retaining Rings
Cooling Design Retaining Ring Design
Diagonal flow Body mounted
Radial flow Body mounted
Conventional cooled Spindle mounted
Conventional cooled Body mounted
Direct cooled Spindle mounted
Direct cooled Body mounted
Nested within the generator identification are the types of auxiliary systems that support the
generator. This identification system identifies additional equipment that may require pre-outage
maintenance planning, outage inspection, repairs, etc. The coding may also help identify a
family of generators that are experiencing very specific maintenance problems and require
special planning before and attention during the outage.
Generators can be broken down into two major areas: stator and field. The purpose of the
generator inspection is to determine the condition of these two areas and evaluate them for
continued reliable service. This may mean repairing conditions found during the outage or
postponing action until a future outage. To accomplish this, each area will receive both
mechanical inspection and electrical testing during the outage.
The EPRI report Guide for On-Line Testing and Monitoring of Turbine Generators, 1006861,
[38] describes a variety of generator on-line monitors and generator detectors. The guide is in the
form of a spreadsheet where a user can specify the generator they are inspecting and then get
extensive technical help in the form of a detailed failure mechanism and monitor description.
These results can assist with defining the most appropriate on-line detection system.
When considering the replacement of the generator rotor or stator, Sections 8 and 9 and
Appendices E and F in Volume 4 of these Guidelines will guide the utility engineering and
purchasing organizations through the process of procuring a generator stator rewind or an
entirely new generator stator.

5-58
While preparing these procurement specifications, many engineers may not be entirely familiar
with the terms and technical implications of these specifications. The following is a list of
references that will further the technical understanding of these terms:
G. Klempner and I. Kerszenbaum. Operation and Maintenance of Large Turbo-Generators.
IEEE InterScience Series, Wiley Press, 2005.
M. G. Say. Alternating Current Machines. Pitman Publishing, 1978.
E. Fitzgerald and C. Kingsley. Electric Machinery. McGraw-Hill, 1971.
IEEE Guide for Operation and Maintenance of Turbine Generators. IEEE Std. 67-2005.
General Electric Company. Generators for Utility and Industrial Applications. GE Industrial
Power Systems, GET-8022, October 1992.
5.17.2 Generator Stator
The stator core serves a mechanical and an electrical purpose. The mechanical purpose is to
support the stator winding. The electrical purpose is to provide a return path for the lines of
magnetic flux induced by the field. A visual inspection of the stator core starts with carefully
inspecting for signs of localized heating or damage of the core inner surface. The stator core is
comprised of enameled insulated punchings that are assembled to a key bar. Overheating of
the punchings can occur at the inner diameter (air gap) if enough punchings are damaged and are
shorting together. In some cases, as few as two laminations shorted together would mean a repair
and restacking of the core would be necessary.
Hydrogen-cooled generators require paying particular attention to this when inspecting. An oxide
builds up on the overheated area and limits conduction, eventually limiting the overheating in
air-cooled generators, but in hydrogen-cooled generators, there is no oxygen to limit the process.
Removing the damage with a de-burring tool and re-insulating the punchings can restore these
areas.
During their inspection, the windings can be tested to determine if they have been affected by
thermal aging. Electrical insulation used in stator and rotor windings has a major impact on the
reliability of large motors and generators. Insulation failure, whether direct or indirect, will result
in machine failure, which leads to forced outages, reduced reliability, increased maintenance, and
repair costs. EPRI report Testing of Stator Windings for Thermal Aging: Interim Results,
1004557, [39] deals with this issue by correlating thermal aging of stator coil/bar insulation to
dielectric changes measured at frequencies other than 60 Hz. This project has not been
completed, but the results so far have shown that measuring the dielectric changes in the test
insulation with non-60 Hz techniques can identify aging. This project should be complete in
2003 and can help improve maintenance of stator windings.
The punchings are also inspected for movement. Normally, clamping force from the stator
clamping flange holds the punchings tightly together. The telltale sign is dusting or greasing,
which is a dark, spotty accumulation if a punching is moving. Generator construction normally

5-59
limits access to the backside of the punchings and the attachment to the key bar. This area is
inspected from the ends and ventilation areas to look for movement between the punchings and
the key bars.
Baffles can be either installed at the ends of the core or mounted to the inner end shield. The
baffles should be inspected for cracking in the mounting hardware or the supports, vibration, or
fretting, especially at any possible locations of contact with the windings. The attachment
hardware should all be nonmagnetic.
Stator windings pass through slots in the punchings and wedges retain the windings. The wedges
are inspected for looseness or movement by using a small ball peen hammer and tapping the
wedge, feeling and listening for changes in sound. Some wedge movement and fretting may be
the result of slight movement of the core during normal operation. The corrective action will
depend on the type of generator insulation and wedges.
A numbering convention should be used to identify the wedges. Generally, a numbering
convention begins at one end of the generator and numbers in ascending sequence along the
length of the slot to the other end. The usual convention is to number from the turbine end to the
collector end of the generator. The numbering convention will also include a radial orientation
for the slot location.
Typically, the radial location begins with a top bar referenced to one of the terminal connections
and increases with reference to the rotation of the field. The stator windings have three areas of
inspection: the slot portion through the core; the end winding area past the core; and the end
windings support system. Borescopes are used to increase the range of the inspection when
examining the stator windings. Excessive winding movement and vibration may be detectable by
borescope examination through the ventilation ducts.
Dusting on the side of the bar may be evidence of undesirable bar movement. Bar action may
also cause chafing on the slot armor cutting through the armor. High-current generators are more
susceptible to bar movement and vibration because the forces exerted on a bar during operation
varies approximately as the square of the current. The type of insulation used in the construction
of the bars is also a factor in how much movement and vibration may exist during operation.
The end windings should be inspected for signs of relative movement that may be expressed as
cracking in the taping. The copper bars expand at a different rate than the iron core; therefore,
the copper bars may have a tendency to expand faster and more than the core as generator
loading is changed. Insulation changes that better contain the windings have helped to reduce
this condition. Inspection and repair requirements may extend beyond the end windings into the
ends of the core if cracking conditions are found. Inspection of the end windings also includes
looking for any looseness or relative movement between components.
The condition of the stator winding insulation system for a turbine-driven generator can be
checked by partial discharge (PD) and electromagnetic interference (EMI) on-line testing. These
tests can offer advantages in avoiding prolonged generator shutdown for off-line tests and
inspections. PD is a time domain measurement, and EMI measures activity with a frequency
scan. Both tests evaluate high-frequency currents that flow as a result of electrical discharges

5-60
occurring within the structure. The EPRI report Assessment of Partial Discharge and
Electromagnetic Interference On-Line Testing of Turbine Driven Generator Stator Winding
Insulation Systems, 1007742, [40] evaluates the tests and gives an appraisal of their
effectiveness. The results show that systems being able to monitor activity over time can add
another dimension to the diagnostic process.
Broken ties, loose or missing blocks, distortion, or cracking may all be evidence of high-level
generator response to faults or system disturbances. These are repaired by securing, reinforcing,
and re-taping. The end windings may also display signs of corona. Typically, these would be
seen as whitish, brown, or yellowish accumulation of discolorations. Minor corona deposits are
typically just cleaned off, but more intense activity may require providing bridges to dissipate
the surface charge.
Many later design generators must deal with stator bar liquid connection problems. Generally,
the hose connections are inspected for movement, abrasion, fretting, cracks, or surface
contamination. It is important to keep the hose surfaces clean because dirt or other substances on
these surfaces can form a creepage path to ground. The corrosion of the brazed bar end
connections is an additional problem you must be aware of. This area is inspected using a
hydraulic integrity test (HIT). Leakage in this area may result in wet bars, ends, etc. A variety of
repair methods are available today. Some repairs include epoxy injections that repair and seal the
area from addition corrosion.
It has been found that water-cooled generators have clip-to-strand leakage due to localized
crevice corrosion as referred to above. EPRI has investigated this problem, and report
Conversion to Deaerated Stator Cooling Water in Generators Previously Cooled w/ Aerated
Water: Interim Guidelines, 1000069, [41] outlines how generator stator coolant water can be
safely and economically converted from an oxygen-rich (aerated) to an oxygen-rich (deaerated)
condition.
With generator cooling systems, there are problems with recirculation and deposition of solid
matter in the cooling water, which can lead to flow restrictions and inadequate cooling of
electrical components. Depending on the magnitude of the flow restriction, various malfunctions
may occur. One example of these is local overheating of a stator bar above the long-term
temperature limit of electrical insulation. Another problem could be the loss of cooling of a stator
bar that leads to overheating or melting of the bar.
Due to unexpected problems, it is useful to have a process that monitors the system for flow
restrictions and to have options for removing them. The EPRI report Guidelines for Detecting
and Removing Flow Restrictions for Water-Cooled Stator Windings, 1004704, [42] gives
guidance in this area. The guide reviews various approaches for detecting and removing flow
restriction in hollow stator bar strands. It provides an appropriate procedure to conduct a visual
inspection that is supported by mechanical means in order to provide the most reliable
information. The guidelines will provide information relating to maintaining the system during
outages and describe improved early monitoring and detection procedures.

5-61
The bushing box (attached to the lower portion of the generator) should be opened and the high-
voltage bushing and stand-off insulators inspected. Both porcelain insulators should be inspected
for damage, cracks, movement, and greasing. All hardware should be inspected for tightness and
appropriate sealing. Leaking of asphalt material on the airside of the bushing box is an indication
of high-voltage bushing overheating.
Abrasion or FOD is the typical damage mechanism to the ID of babbitted steel hydrogen seals.
Rings severely scored (> 0.005" [0.127 mm] deep) over 75% of the surface area should be
replaced. Rings should also be replaced where the design clearance is worn beyond 1.5 times for
3600-rpm machines or two times for 1800-rpm machines. Air tightness test results or hydrogen
consumption beyond design or expected values may also indicate excessive clearance.
Electrolysis damage may also occur to hydrogen rings. The hydrogen seal casing is fastened to
the outer end shield, and typically, the collector end hydrogen seal assembly is insulated from the
outer end shield. The insulated hydrogen seal casing is assembled with insulating sleeves around
the bolts and insulating washers under the bolt heads; no conduction paths should exist though
the assembly. Insulation resistance should be checked with a megger and should be greater than
100,000 ohms. If megger readings are low, the assembly should be disassembled one bolt at a
time to determine the possible shorted location.
Oil deflectors should be checked for clearance to the shaft. The inner oil deflector should
especially be checked if there is oil leakage into the generator. The inner oil deflector may also
leak oil into the generator from a previous poor assembly or lack of seal to the bolting face or at
the horizontal joint.
Generator bearings may experience the same problems and would require the same repair
techniques as turbine bearings; both issues are addressed and outlined in Section 5.10. An
insulation requirement may be the one difference from the turbine bearings. One bearing, usually
the collector end bearing, will be insulated. This bearing should be checked with a 500 volt
megger, and a minimum of 100,000 ohms resistance is required
Units with a hydrogen cooler should be inspected for signs of vibration damage or breakage to
the structural supports strengthening the cooler. Repairs are made by:
Protecting the tube bundles and fins
Taking precautions to reinforce the cooler structure by attaching the cooler to wide flange
structural beams or strong backs to prevent distortion, sagging, etc. during the repairs
Weld repairing or strengthening and then weld repairing the damaged area
Recoating the structure
An inspection of the cooler support structure within the generator should be done if repeated
cooler damage is observed. The cooler is designed to be equally supported along its entire length.
If there are large changes in elevation between the support rails and the cooler openings or if the
support structure is not level, the cooler may significantly deflect or vibrate in service causing
cracking in the cooler bundle structure.

5-62
The EPRI report Generator Cooling System Operating Guidelines: Cooling System Maintenance
and Performance Guidelines During Start-Up, Operation, and Shutdown, 1004004, [43]
provides operating guidelines that apply to systems with either high or low dissolved oxygen
(DO) concentrations. This report provides a cooling system maintenance and performance guide
for application during startup, operation, and shutdown.
An easy way to assess this condition is by stretching a wire between the cooler openings and
evaluating the position of the support rails in relation to the cooler openings. The cooler support
structure should have less than 1/8" (3.2 mm) deflection between the structure and the wire at
any point. Modify the rails position or support structure as necessary. Another indication of
cooler support structure issues may be reflected in the difficulty of cooler removal or insertion.
The cooler may hang-up during these activities. The tube and fins of the cooler should be
inspected for any signs of leaks. The cooler heads are inspected for corrosion. The cooler heads
may require sandblast cleaning and then adding a corrosion-protection coating.
The generator produces an electrical potential induced into the generator field during normal
operation. Shaft grounding brushes are usually installed near the coupling between the turbine
and generator to provide a ground path for the potential difference. Recent preliminary studies
have shown that it is not only the generator contributing to the potential difference of the HP
turbine to the generator rotor train, but the LP rotors also build up a potential as water droplets
are stripped from the last stage buckets. The LP rotors may also retain a magnetic field as they
age, induced by any repair welding on the rotor, induction heating, or by the MT inspection
performed on the rotor. Residual magnetic fields should be inspected and, if significant,
degaussed as an outage activity.
Further studies of the turbine are being performed and should shed some light on the total impact
and significance of LP rotor contribution to the total rotor train potential. If the potential
difference were not grounded, it would seek a ground path though either the oil film of a bearing
(or bearings) or the hydrogen seal. Electrolysis of either location would result. It is good
maintenance practice to monitor the grounding brushes during normal operation to ensure that
they are clean and in contact with the rotor. During an outage, they should be inspected,
reassembled, and tested as soon as the unit is returned to service.
5.17.3 Generator Field
The field collector rings should be checked for vibration prior to the outage to provide a preview
of the collector ring condition. A dowel rod is used between the transducer and the brushes to
obtain the collector ring vibration. Choose a brush location in approximately the same angular
position as the other vibration pickups on the turbine-generator (yields approximately the same
reference location and orientation for vibration equipment).
A good operating collector ring and brushes will have a vibration level in the range of 23 mils
(0.050.76 mm); up to 6 mils (0.15 mm) is satisfactory. Readings of 1020 mils (0.250.50 mm)
may be experienced when there are problems. Vibrations normally increase as the collector ring
wears. The wear is usually seen as peaks and valleys caused by the different brushes.

5-63
Vibration may be caused by a condition known as photographing where the brush bounces and
loses contact with the collector ring, resulting in an image of the brush on the surface of the
collector ring. High vibrations may mean mechanical problems with the rings such as potentially
loose parts or misalignments, but often this vibration is caused by the condition of the rings.
It may be possible to balance the collector rings, but because the cause of the vibration is the
condition of the rings, it is necessary to correct this vibration by machining or grinding the
collector rings. Rings can be machined as long as there is sufficient spiral groove depth
remaining (plan on replacing rings when this groove in a minimum 1/16 [1.6 mm] depth) after
machining the rings to an 8 microinch (0.203 micrometer) finish.
Collector rings may either be ground in the machine while on turning gear, in a rotor turning
device during an outage, or in the machine at speed. Each process has its advantages and
disadvantages; some of those are listed in Table 5-15.
Table 5-15
Alternative Processes for Grinding Collector Rings
Operation Advantage Disadvantage
Turning gear Usually non-critical path. Done between
getting on turning gear and unit startup at
the end of the outage.
May be centrifugal effects on
rings.
Rotor
turning
device
Non-critical path. May be centrifugal effects on
rings. Equipment availability.
At speed Remove centrifugal effects on rings. Critical path activity.
A review of brush wear rate may also provide information regarding the condition of the
collector rings. Typical brush life is 36 months, and the brushes should wear at a rate of
approximately 350 mils (8.9 mm) per 1,000 hours of operation. The corresponding wear rates
of the collector rings should be 1 mil (0.3 mm) per 1,000 hours of operation. Excessive wear
rates indicate poor performance of the brush-ring assembly. A collector ring wear rate of 5 mils
(0.13 mm) per 1,000 hours of operation would indicate poor performance.
Wear comes from both mechanical abrasion and electrical arcing. Minute electrical arcing begins
to occur after the ring is worn a few mils and the brush contact begins to change. The brushes
may tend to chatter and chip as brush temperature rises from the loss of contact if the condition
worsens. The rings can be visually inspected after the field has been removed. The rings should
be inspected for grooving, cutting, uneven wear, and surface coloration. Only minor surface
damage from handling may be dressed and blended with a stone.
A darkish-brown coloration on the collector rings is an indication of good brush-ring contact and
operation. The coloration is from a film of hydroscopic brush material residue that has collected
and is adhering to the collector ring surface. The composite film then acts as a lubricant between
the brush and the ring, reducing wear.
The collector rings sit outboard of the collector end outer end shield, and the field windings are
inboard of the collector end inner end shield. There is a connection between the collector rings

5-64
and the field windings that is made through a conductor that passes through the field bore and
then emerges between the fan ring and the field windings under the retaining ring. The bore
conductor is connected to the main lead through a field terminal stud shown in Figure 5-7. There
is a seal around the terminal stud on hydrogen-cooled units to prevent the hydrogen gas from
leaking into the bore and exiting around the collector rings.

Figure 5-7
Terminal Stud Hydrogen Seal Construction
The seal is inspected for tightness as part of the outage inspection. If possible, check the
hydrogen seal while the unit is still on turning gear and pressurized with hydrogen using a
hydrogen sniffer.
Certain main lead designs (solid lead, hollow and ventilated) experience a combination of high-
cycle and low-cycle fatigue in the 90-degree bend where the lead turns away from the field body
and radially toward the windings. See Figure 5-8. The problem is a result of centrifugal loading
caused by the main lead; the loading is transferred to the lead wedge and the #1 coil. Therefore,
damage may also be seen in the lead wedge and the #1 coil end strap.

5-65

Figure 5-8
Location Susceptible to High-Cycle Fatigue and Low-Cycle Fatigue in Certain Main Lead
Designs
These components are visually inspected with a borescope and red dye PT. The end turns can
also be inspected with the retaining rings in place for distortion, loose or moved blocking,
discoloration, or debris using articulating mirrors and borescopes. The retaining rings must be
removed if damage is found. The retaining rings have been identified as the highest stressed
component of either the turbine or the generator. Therefore, special care must be taken to prevent
adding any stress risers from nicks or dings to the retaining rings.
The outside diameter of the retaining ring may be PT or MT inspected with the retaining ring in
place. But the ring must be removed to inspect the internal diameter with either PT or MT. UT
techniques are being developed to inspect the condition of the inside diameter with the retaining
ring in place. Current retaining ring removal practice uses high-frequency induction heating, but
older methods include both flame heating and resistance blankets. Flame heating required
additional protection to prevent flame impingement on the nonmagnetic retaining ring surface.
The field slot wedges can be visually inspected with the retaining rings in place. The wedges are
inspected for mechanical damage of nicks, gouges, etc., and electrical damage of overheating.
Excessive circulating surface currents cause the overheating. The wedges may require removal if
the overheating damage is severe. Good contact between the wedges and body is required to
prevent overheating. Arcing and overheating reduce the conduction between the wedge and the
body. The retaining rings must then be removed to remove the field slot wedges. The wedges are
then removed, glass-bead cleaned, inspected, and reinstalled.
Hydrogen-cooled generators use body-mounted fans on each end of the field to circulate
hydrogen through the generator. The fans may either be single stage or multiple stages.
Typically, single-stage fans are used with liquid-cooled stators, and multiple-stage fans are
required for gas-cooled stators.
The field-mounted fan segments should be inspected for tilting, gaps between the blade hubs and
blades for single-stage fans, proper fan ring clearances, rubbing, and other problems while being

5-66
removed from the rotor. The segments should be numbered in the order of their removal and
referenced to a specific rotor location. The removed fan segments should be inspected using an
appropriate NDE method. Older units may have steel segments, but newer units are made from
aluminum. The anticipated indications would be cracking or other mechanical damage.
The rotor surface at the hydrogen seal areas, oil deflectors, and rotor journals should be inspected
for damage, including grooving, scoring, and damage from previous assembly or disassembly.
Minor damage may be strap lapped, but severe damage will require machining of the surface.
Strap lapping cleans and polishes the rotor surfaces. The grit of a coarse grit emery paper is
broken down first before using on the rotor. Straps 3/81/2" (9.512.7 mm) wide are wrapped
one-and-one-half turns around the shaft and pulled back and forth. Strap lapping also enhances
the oil-carrying capability of the rotor surface.
5.17.4 Generator Electrical Testing
Electrical testing is performed to both generator components as a normal part of generator
maintenance. Electrical testing can provide damage expectations and condition assessment when
it is used as a diagnostic tool. During reassembly, electrical testing provides assurance that the
assembled components will function as intended after the outage. Table 5-16 summarizes some
of the tests that can be performed. Sections 5.17.4.1, 5.17.4.2, and 5.17.4.3 provide additional
details on most of these electrical tests.
Table 5-16
Generator Electrical Tests
Test
D
i
a
g
n
o
s
t
i
c

A
s
s
e
m
b
l
y

Area Condition Tested For
ac impedance X Field turn insulation Turn shorts
Capacitance mapping X Stator water-cooled windings Wet ground wall bar insulation
Copper resistance X X Field and stator Poor connections and opens
dc leakage current X Stator winding Deterioration or contamination
Doble X Stator winding Insulation integrity
EL CID X Stator core insulation Weak or damaged core
Helium gas X X Stator water-cooled windings Leak detection
Hi POT X X Stator winding Insulation integrity
HIT X Stator water-cooled windings Water leaks
Megger X X Stator, field, bearing, H
2
seal Insulation: condition, assembly
Partial discharge X Stator windings Localized deterioration
Sniffer X Stator assembly Leak detection
Wedge tightness X Stator wedges Loose wedges, losing tightness

5-67
An alternative to taking the generator field rotor from the stator to perform inspections is to use a
limited access inspection (LAI). Limited access inspection (LAI) provides generator component
assessments using robotic technology without removing the rotor. This type of testing is
comparable and very often superior to conventional inspections with the rotor removed. The
EPRI report Experience with Limited Access Generator Inspections: A Study of Inspections Done
with Robotic Equipment and their Effectiveness as Compared with Conventional Inspections
Where the Generator Rotor Is Removed, 1000100, [44] is a compilation of 68 LAIs from 1995
1999 of two major OEMs (Siemens and General Electric) and original video tape of the
inspections. The report lists the applications and capabilities of LAIs, demonstrates how LAIs
compare to conventional assessments, and shows a cost comparison of LAIs versus conventional
rotor out inspections. LAI has been accepted by the Nuclear Electric Insurance Limited (NEIL)
as an equivalent rotor-out generator inspection.
Applications and Capabilities of LAIs
The LAI is used to replace the routine and periodic rotor-out inspections where the rotor is
physically removed from the stator by major disassembly of the end shields, bearings, oil
deflectors, baffles, seals, etc. Conventional methods can possibly cause major damage to a rotor,
and the inspection is time consuming and very costly. Although some disassembly is still
required by LAIs, it is quite minimal compared to conventional methods and will vary depending
on the LAI vendor, the size of the unit, the type of unit (nuclear or fossil), the manufacturer of
the unit, and so on.
LAIs have many of the same capabilities as conventional inspections. LAIs can still visually
inspect a generator for tell-tales and defects, perform a stator slot and bar assessment,
complete a stator end-winding inspection, and execute a rotor field visual inspection. The video
records can now be recorded and archived for future reference. Very often, many specialists like
to use a touch and feel method with some areas of the generator to better inspect components.
Although LAIs do offer a similar capability, some say that it is not exactly comparable. Table 5-
17 shows a comparison of LAI capabilities compared to conventional inspections. Note that the
LAI has all of the same capabilities as the conventional rotor-out method.

5-68
Table 5-17
Capabilities of LAI vs. Conventional Inspections
Generator Component LAI Conventional Inspection
Wedges/Slots - -
Dusting/greasing X X
Tightness X X
Bar movement X X
Discharge (corona. . .) X X
Contamination X X
Wear/damage X X
Core - -
Dusting/greasing X X
Overheating/shorts X X
Wear/damage X X
Blocked Vent Ducts X X
Field - -
Surface Heating X X
Wedge movement X X
Vent holes X X
Contamination X X
Hardware X X
Retaining rings X X
Blocking/filler movement X X
End turn problems X X

5-69
Advantages and Disadvantages of LAIs
There is no doubt that LAIs will save maintenance costs when compared to rotor-out inspections.
The amount of savings depends upon the individual plants situation and economics such as:
Amount of disassembly required
Confined space restrictions
Amount of station support required
Length of inspection
Reassembly material required
Crane requirements
Rotor storage/protection
Rotor alignment
Risk of damage to rotor, stator, and other components
Risk of oil leak introduction
Foreign object material damage potential avoidance
LAIs have some small risks associated with it; however, they are smaller than the potential risk
associated with pulling the rotor. (Table 5-18 presents a list of advantages and disadvantages of
LAIs.) Issues such as a stuck robot inside the unit have not really presented themselves. Loose
hardware falling off the robot and getting lost in the stator has been controlled by the use of
standard industry locking devices (that is, safety wire, thread locking compound, plastic
hardware, self-locking nuts, etc.). There have been some cases where the robot was unable to
access the generator due to the baffling or other unusual dimensional access issues; however,
these are usually the exception.

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Table 5-18
Summary of Advantages and Disadvantages of LAIs
Advantages Disadvantages
Better technology cameras, wedge tappers, El
Cid
Limited touch and feel capability in slots and
on rotor body
Convenience Exaggerated condition possible based on poor
evaluation
Reduced cost Evaluation more dependent on evaluators
experience
Reduced outage duration Possibility of compromised and damaged shaft
insulation
Deferred rotor removal Other inspections possibly overlooked
(bearings and seals)
Potential damage from rotor removal eliminated Interpretation and evaluation too often
simplistic not enough relevant comments on
condition
Permanent video record
Frequently higher quality reports
Outage interval extension facilitated
Excellent application for mis-operation internal
inspection

More accurate tell-tale positioning data
Better trending capability/records
Decreased potential for foreign object damage
Consistent with turbine LAI strategies
Over 10 years of experience with LAI
LAIs should be strongly considered as a universal substitute for rotor-out inspections. LAIs, in
addition to maintenance and operations history and standard tests, provide some of the essential
ingredients for an overall comprehensive maintenance program. There may be extenuating cases
where further investigation may require pulling the rotor after an LAI is performed based on the
need for further inspection and testing of unique situations; however, this should be the
exception.

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5.17.4.1 Generator Stator Core Electrical Tests
5.17.4.1.1 EL-CID Testing
The EL-CID technique was originally devised as portable test equipment for inspection and
repair of rotating electric machine stator cores. It was devised as a low excitation power
alternative to the high power level stator core flux test, for looking for stator core inter-laminar
insulation problems. Its application has been shown to be applicable to turbine generators,
hydraulic generators, small generators and large motors. The subject of this book however, is
confined to the class of large 2 and 4 pole, round-rotor machines, commonly referred to as
Turbine-Driven Generators.
The information contained in this section is a brief discussion of the EL-CID test technique and
basic interpretation of results.
Traditionally, stator core inter-laminar insulation testing has been done using the Ring or
Loop flux test method, in which rated or near-rated flux is induced in the stator core yoke. This
in turn induces circulating currents from the faulted area usually to the back of the core, at the
core-to-keybar interface (see Figure 5-9). These circulating currents cause excessive heating in
areas where the stator iron is damaged. The heat produced is generally detected and quantified
using established infrared techniques. This method has been proven to be successful over the
years, but requires a large power source and considerable time, manpower and resources to
complete.
Starting at the early 1980s, the EL-CID test has been developed as an alternative to the ring flux
test. The technique is based on the detection of core faults by measuring the magnetic flux
resulting from the current flowing in the fault area, at only three to four percent of rated flux in
the core. Furthermore, the test usually requires only two or even one man to complete (using the
latest version) in less than one eight-hour shift.

5-72

Figure 5-9
Flux Fault Current Path (Courtesy of IEEE 2004)
5.17.4.1.1.1 EL-CID Test Procedure
The level of excitation to produce the desired flux in the stator core-back area is generally
determined by a combination of the stator design parameters, and the power supply available to
achieve the required flux level. For most generators, the standard 120 V AC (North America,
etc.) or the 230 V AC (Europe, etc.) outlet, with a current capacity of 15 to 20 amperes is usually
adequate.
The characteristics of most stators are such that 4 to 7 turns of a #10 AWG insulated wire (2.5
mm
2
) can be used to carry the excitation current for the test. The winding is then energized to the
required volts per turns, to produce approximately 3 to 4 percent of rated flux, usually
corresponding to around 5 volts per meter across the stator iron. A Powerstat or Variac is best
used for voltage and supply current control.
The signal-processing unit of the EL-CID test equipment measures detected fault current (in
QUAD mode) in mA. By theory and experimentation, a measurement of at least +/- 100 mA is
required at 4% excitation of the core before it is considered that the core has significant damage
affecting the inter-laminar insulation.

5-73
The excitation winding and power supply are set-up during the test as shown in Figure 5-10.

Figure 5-10
EL-CID Excitation Setup (Courtesy of IEEE 2004)

5-74
The EL-CID equipment is set up as shown in Figure 5-11 (original analogue set), and Figure
5-12 (newer digital set).

Figure 5-11
EL-CID Analog Equipment (Courtesy of IEEE 2004)

5-75

Figure 5-12
EL-CID Digital Equipment (Courtesy of IEEE 2004)
In the older analogue sets, a separate coil is placed in the bore over undamaged iron as shown in
Figure 5-11, to supply the reference signal. In the newer digital version, a CT (shown in Figure
5-12) is placed around the excitation winding to reference the supply signal. The CT was also an
option on later analogue sets. The digital equipment uses a laptop computer to store the axial
traces, whereas a plotter was used in the original version.
The sensor head (chattock potentiometer) is pulled axially along the core at a speed slower than
one meter every twenty seconds and always bridging two stator teeth as shown in Figure 5-13.
(The slower speed is important, as the standard chattock coil has a magnetic sense area of only
4mm diameter, and both the Digital and Analogue systems have a definite time needed to record
the Phase/Quad signals to sufficient resolution. The Digital set records the Phase and Quad
values every 2mm. Any faster testing results in some missed test points in the Digital system or
potential inaccuracy due to settling time on the Analogue system).

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Figure 5-13
EL-CID Chattock Theory (Courtesy of IEEE 2004)
The fault current signal is read directly off the signal processor meter, and input to a computer or
chart recorder to trace out the readings as a function of the axial position along the stator core.
When the sensor head is over undamaged iron, the meter should read zero if it is calibrated
previous to the test for a condition where no fault current is circulating. In actual practice, no
insulation system is perfect and some background signal is usually detected. In addition, the
contact resistance of the core to keybar interface is not zero and can be found to vary between
near 0 to 2 ohms. This also affects the EL-CID signal that is measured. Usually anywhere from a
0 to +/- 20 mA EL-CID signal (in Quad mode) is found to be normal when good core is
measured.
The above is somewhat similar to the rated flux test where the undamaged iron slowly heats up
producing a background level due to eddy current losses in each lamination. During flux testing,
this is recorded as the ambient core temperature rise. Where there is damaged or deteriorated
core insulation, the core overheats and is detected as a hot spot above core ambient due to high
fault currents circulating locally.
In the EL-CID test, when the sensor head is placed over damaged core areas, the primary
indication of a fault is obtained by detecting the flux produced by a current flowing in phase
quadrature with respect to the excitation magnetizing current (the PHASE current). This flux is
then converted back to an indicated current (the QUAD current), assumed to be flowing in the
fault (see Figure 5-14). For this reason the QUAD current detected by the EL-CID processor is
frequently referred to as the fault current (although for large faults the PHASE current may be
affected as well, especially where the fault current path is highly inductive). The QUAD current
is indicated on the signal processor meter and the traces recorded on the plotter (original
analogue EL-CID equipment) or computer (newer digital EL-CID equipment).

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Figure 5-14
EL-CID MMF Theory (Courtesy of IEEE 2004)
5.17.4.1.1.2 EL-CID Experience
EL-CID has proven to be extremely reliable in detecting and locating core problems. It can cut
the time and manpower requirements for core testing to within one eight-hour shift, where a flux
test may have taken a few days to set up, and then a day to test, and another day to dismantle the
test equipment.
In the large majority of the EL-CID tests on turbo-generator machines, the experience has been
that EL-CID is very reliable in determining that actual core faults or inter-laminar insulation
deterioration exists. In other words, if a core defect exists, then EL-CID is likely to find it. And if
the core is indicated to be defect-free by an EL-CID test, there is a very high probability that it
actually is free of defects.
Large signals may be found at tooth-top locations on the core, and only indicate a significant
surface fault. Local surface faults are generally indicated by faults that show very localized
signals, either high or low in magnitude and positive in polarity, if within the test coil span
(assuming the standard EL-CID test set-up). Deeper faults can generally be seen over a larger
scanning area, and also often become opposite in polarity as the sensor head gets away from the
fault area. This is because the fault is outside the flux path of the chattock coil sensing the fault
current, and the magnetic potential difference is reversed.
Figure 5-15 shows a general basic interpretation of the EL-CID signals that can be expected to be
seen based on fault location. The magnitudes in Figure 5-15 are only relative to one another, to
give an idea of what might be expected for faults of roughly the same severity, at different
locations. The peaks, and widths of the peaks, will vary from fault to fault as their size varies,
and as they are more or less severe.

5-78
Attempts have been made to correlate EL-CID signal readings to temperatures that would be
created in the defect area, during a flux test. The basic premise of the EL-CID test significance
level of +/-100 mA is, that this level represents a 5 to 10C temperature rise that would be seen
on flux tests, and therefore, just at the level of temperature rise where most OEMs and
experienced stator core experts would carry out repairs to the core iron.
There are a number of issues that makes questionable the assumption that correlates EL-CIDs
signal to temperature. Firstly, many core testers carry out flux tests at widely differing flux
levels. Some prefer to test at 100% of rated flux level while others test at about the 80% level.
Different operators also apply the flux test over widely varying time periods. Yet, by all
indications, all seem to work on the same temperature rise criteria. Obviously, a 10C rise at
100% of rated flux is much less significant than at 80% of rated flux. This is so because the 80%
level is generally at the knee of the B-H curve and the curve is exponential. Increasing to 100%
when the temperature rise is already 10C will increase the temperature in the fault.
There is also the influence and undetermined significance of core-to-keybar contact resistance at
the back of the core. The concern here is that the resistance can be generally measured to vary
from near 0 to 2 ohms and may affect the EL-CID signal as well as the temperature measured
during a flux test.
For the low flux levels of the EL-CID test, it may be quite significant. This is one of the
unknowns for which there is little data to support this statement, one way or another. But it
should be noted that on ungrounded cores (i.e. cores with insulated keybars and infinite core to
keybar contact resistance), the EL-CID and the flux test are both ineffective unless there are two
faults in proximity, to allow circulating current to flow and hence be detected by either test. This
has been well proven by actual tests done on such cores, where single faults do not show up until
the core is artificially grounded at the back near the keybar that is behind the location of the
fault.

5-79

Figure 5-15
EL-CID Signal Interpretation (Courtesy of IEEE 2004)
Generally, there is only one keybar that is grounded on such core arrangements (for purposes of
the stator ground fault relay), and the testing is effective in that lamination region only, for single
faults. To test such a core arrangement by either EL-CID or flux test, the core must be purposely
grounded at the back, between every keybar, circumferentially, and on every lamination axially.
One can easily see the difficulty in this, as it is not even possible on most stator designs, because
of the frame construction and arrangement. One has to consider this when purchasing a new
stator. If a single core fault occurs, then the insulated core may allow operation where the
grounded core would fail based on the progression of the fault. However, if two faults occur in
the same proximity, then a much more severe fault may occur and go undetected until the effect
of the failure causes additional collateral damage, which takes the machine out of service. This is
generally a matter of user preference and both philosophies are sound, each in their own way.
In addition, there is also the problem that core faults can manifest themselves in many forms and
levels of severity. It is not uncommon for a surface iron smudge to show a very high EL-CID
signal and yet not produce much heat when looked at under infrared in a flux test. And the
opposite is also true. It is not uncommon for an EL-CID signal that is not much higher than the

5-80
manufacturers recommended significance level, to produce significant heat. In particular, with
very small faults on the surface where EL-CID does not produce a significant signal, there are
sometimes high spot temperatures detected by infrared, but there is insufficient power to cause
damage.
One advantage is that EL-CID can detect deep-seated faults, which may often not show as a
particularly large temp rise on the surface, but can be quite damaging to the body of the core or
adjacent conductor bar insulation. This is due to the fact that the attenuation of EL-CID signals is
generally less than the attenuation of temperature rises with depth of fault.
The difficulty in co-relating EL-CID and Flux test temperatures therefore comes from many
issues as stated above and a number of other possible influences as listed below:
Core-plate grade (i.e. grain oriented vs. non-oriented steels)
Lamination insulation grades
Axial length of the fault
Total size of the fault
Electrical resistance of the inter-laminar fault (i.e. deteriorated or fretted insulation type
damage as opposed to hard contact, low resistance type faults)
Geometry differences in core structure from one machine to another
Limitations of the earlier EL-CID test equipment, in relation to the size of the chattock coil
itself and the relative size of any fault being measured. (Current standard Chattock coils have
only a 4mm diameter magnetic sense area, thus are able to detect very small faults,
particularly if the suspected fault area is investigated/scanned slowly enough).
All these issues can have a significant effect on both the EL-CID signal seen, and the
temperature produced during a flux test. Some are better known and quantified than others.
Trying to correlate temperatures to EL-CID signals under so many variables is difficult, unless
all of these parameters can be taken into account. In other words, the core under test must be well
known to be able to make such a correlation.
There is one other factor regarding EL-CID signal interpretation, and it has to do with readings
taken in the Phase mode, as opposed to the normal Quad mode reading that Figure 11-8 is based
on. Basically when a stator has (for example) 4 turns of an excitation winding and is carrying 12
amps, then it has an excitation level of 48 Ampere-Turns. When the EL-CID signal processor is
set to Phase mode and a reading is taken from tooth centre to tooth centre across one slot, a
signal of (48 A-T divided by 48 slots) 1 amp should be read. Generally, for most fault areas this
is the reading that will be seen. However, in some cases, much higher current is read in the Phase
mode than the simple magnetic potential based on excitation and slot geometry. One of the
things that has been seen when this type of situation occurs, is that very high Quad readings are
generally also present and the fault is usually at the bottom of the slot, or in the core yoke area.
Correspondingly, there is not always much heat given off during flux testing, and the two tests
do not always correlate when this occurs. There is very little experimental data on this point, and
again it shows that some uncertainties remain in interpretation of EL-CID test results. It is

5-81
believed that Phase readings are also significant and should be factored into the test
interpretation. Just what that interpretation should be is unclear to date, due to the difference in
faults from case to case.
Probably the main difficulty for the test interpreter is, when nothing is known about the core
under test nor the type of fault found. Most often, the core defect is not visible, and what the
tester is trying to determine is how deep it is and how severe it is. The general consensus of the
people surveyed on this issue, is that more often than not, they cannot tell how severe a detected
fault is, and thus require a flux test with infrared scan to help in that determination. The Ring
Flux test remains the best test to determine the actual temperature rise of any fault, and if repairs
are required. If the suspected fault is believed to be deep-seated from the EL-CID test result, the
Ring Flux thresholds should be appropriately adjusted. Once the core is repaired, an EL-CID test
can usually show that the repair is successful by the absence of a defect signal. This is perhaps
the best value in EL-CID testing.
There seems to be general consensus that if an EL-CID test is performed and no damage is
found, then the core is defect free. EL-CID has gained good credibility in its ability to determine
and locate the presence of faults, and to verify repairs when faults are found. The general
consensus also appears to be that more work is required on EL-CID signal co-relation with
temperature rise in fault locations.
The general feeling to date is that both the EL-CID and Flux Testing together are still required to
give the best information on any core defect found.
5.17.4.1.2 Rated Flux Test with Infra-Red Scan
The Rated Flux test is a high-energy test, used to check the integrity of the insulation between
the laminations in the stator core. It is also commonly referred to as the Ring Flux test, in
which near-rated flux (normally about 80%) is induced in the stator core yoke. This in turn
induces circulating currents and excessive heating in areas where the stator iron is damaged (see
Figure 5-9). The heat produced is detected and quantified using established infrared techniques.
Flux is produced in the iron by looping a cable around the core in toroidal fashion (see Figure 5-
16), and circulating a current at operating frequency. The flux required for the flux test is half the
normal operating flux due to the difference in the way the flux is induced in operation (see
Figure 5-17) from that of the flux test.
The power supply for the cable is usually taken from two phases of one of the high voltage
breakers (i.e. 4 kV) in the plant, or a portable motor generator set. The correct number of turns
are looped around the core to produce the required level of flux. IEEE Std. 432 [11] provides the
following expression to find the rated volts per turn required on the stator core:
Voltage per turn of test coil = (1.05 * V
LL
)/(2 3 x K
w
* N)
Where:
V
LL
= line-line voltage
K
w
= winding factor
N = Number of turns/phase in series in the stator winding

5-82

Figure 5-16
Toroid Wrap (Courtesy of IEEE 2004)

Figure 5-17
Operating Flux Pattern (Courtesy of IEEE 2004)

5-83
From the above, the available power supply voltage is divided by the calculated volts per turn
above, to give the correct number of turns to loop through the core. If the number of turns
includes a fraction, then the next highest number is used, to reduce the flux level to below 100%
or below rated. Using too high of a flux level can create core damage since there is no cooling on
the core during the test.
Once the number of turns is known, the current capacity is required to size the cable and ensure
the power source can handle the current that will be drawn. Knowledge of the specific B-H
characteristic of the subject core being tested is required for this. In cannot be stressed too highly
that exact B-H characteristic of the stator core should be known in relation to the flux volts per
turn, and the current that will be required from the power source (see Figure 5-18). In many
cases it is unknown, and therefore the number of ampere-turns required must be estimated based
on industry curves for the most likely grade of core-plate that would be used in the machine
under test. A higher end and lower end core-plate grade are usually selected to provide a range of
possible operating characteristics for the subject core. These are selected to provide a range of
possible excitation requirements, based on B-H curves taken from small and large turbo-
generator applications.
From the winding configuration for the subject generator, the power supply available, and the B-
H curves, an estimate can be made for the number of turns required to achieve the required level
of flux for the test. This is generally in the 70 to 90 percent range of rated flux. The current that
would be flowing in the flux cable will depend on the actual B-H characteristic of the stator iron
and therefore, this must be carefully estimated for safety of both personnel and the equipment.
When the B-H curve is in doubt, adding a higher number turns will reduce the level of flux. Then
it follows to successively remove turns and keep recording the current attained as the flux volts
per turn increases. Successive voltage application in this manner can be made until a B-H curve
is created and the proper number of turns found (see Figure 5-18).

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Figure 5-18
B-H Curve Example (Courtesy of IEEE 2004)
The flux test is set up as basically shown in Figure 5-19. The power supply is selected and
connected as shown. The cable is wound through the stator bore the correct number of times, and
connected back to the power supply. Protection for the test cable is set up to provide ground
fault and over-current. The stator core, frame and the windings were all grounded for their
protection and that of the test personnel. The CTs should also shorted at the terminals and
grounded.
Metering is set up to provide measurements of supply voltage and current. A single loop of cable
is installed additionally, to measure the actual flux volts on the stator core during the test. This is
done to provide an accurate measurement of the induce voltage across the core and the level of
flux as well.
In some cases, an infrared, non-reflecting mirror is used to monitor the temperature of the stator
core when angled viewing from outside the stator bore is difficult (see Figure 5-20). The mirror
provides a known surface to accurately measure the temperatures, so that the absolute and
relative rise of temperatures in the core defect areas can be recorded.

5-85

Figure 5-19
Flux Test Electrical Setup (Courtesy of IEEE 2004)

Figure 5-20
Flux Test Mirror Setup (Courtesy of IEEE 2004)

5-86
Once the flux is established in the core, it is kept for at least thirty minutes to one hour. The
temperature of the core should be maintained within values not significantly higher than those
encountered during operation. Under these conditions, the temperature rises in the core are
monitored and recorded while the existence of hot spots is investigated with infrared monitoring
equipment (and possibly a non-reflecting mirror) (Figures 5-21 to 5-23).

Figure 5-21
Infrared Hot Spot Bruce 7 (Courtesy of IEEE 2004)

Figure 5-22
Infrared Hot-Spot Flux Test 1 (Courtesy of IEEE 2004)

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Figure 5-23
Infrared Hot-Spot Flux Test 2 (Courtesy of IEEE 2004)
The temperature rises of the good core areas (ambient core temperature rise) are then
compared to the temperature rise profile of any defective locations found. Once the defects are
located and characterized, repair solutions can then be addressed.
Figure 5-24 shows the relative experience in the industry with the typical types of core faults
encountered, and how they appear during flux testing. It should be noted that these are general
examples and may not be the case for a particular core tested. However, they show the general
trend that the large majority of faults seem to follow.

5-88

Figure 5-24
Flux-Temperature Profiles (Courtesy of IEEE 2004)
5.17.4.1.3 Core Loss Test
Stator core loss is a function of terminal voltage. The Open Circuit Saturation Curve for the core
iron determines it. The core loss for any particular generator is always determined at the factory
by the manufacturer, and is not a test that is generally done at site.
The core loss is determined by the generator being coupled to, and driven by a calibrated motor.
The friction and windage (mechanical) losses are calculated and separated out from the electrical
losses, to provide a value of core loss for the stator [7].
If there is suspected wear of the inter-laminar insulation in the core, on a large scale, it may be
possible that a core loss test could be done to compare the present value to the as new value, to
determine the extent of deterioration occurring. However, the serious challenge of driving the
generator at site with a calibrated motor, for all practical purposes limits this test to the OEMs
factory.
5.17.4.1.4 Through-Bolt Insulation Resistance
There are a few manufacturers that provide through-bolts in their stators to pull the cores tight.
These through-bolts are full-length bolts, inserted axially through the core, through holes in the
core iron. There are many of them located symmetrically around the circumference of the core, a
few inches below the stator winding slots. The ends are threaded and terminated at each end

5-89
through a pressure plate, where a nut is installed to maintain compression, after the core is
pressed to a few hundred psi.
The entire through-bolt assembly is insulated, generally by cured epoxy/glass tape wrap or a
phenolic tube through the core, and an arrangement of insulators at the pressure plates and nuts.
This is done to ensure that the through bolts do not create any short circuits across the stator core
laminations and cause a core failure by circulating currents.
To ensure that the insulation is in good condition, the insulation resistance of the through-bolts is
checked by meggering at 500 V DC. A good reading should be in the hundreds of M range.
5.17.4.1.5 Insulation Resistance of Flux Screens
Most large generators are provided with some form of flux screening for the stator core-end. This
is to prevent overheating in the core-ends due to stray flux from the stator endwinding. When
flux screens are used, they are insulated from the core end, to ensure that no additional
circulating currents flow between the core and the flux screens, which would create additional
un-wanted heating in the core-end.
To ensure that the insulation is in good condition, the insulation resistance of the flux screens is
checked by meggering at 500 V DC. A good reading should be in the hundreds of Mega-ohms
range.
5.17.4.2 Generator Stator Winding Electrical Tests
Stator windings are comprised of materials with specific resistive and dielectric qualities. The
materials used comprise: mica, Dacron tapes, glass tapes, asphalt binders, polyester resins and
epoxy resin binders, and so on. There are also insulating, resistive and stress grading paints
applied to various portions of the winding to ensure controlled distribution of the voltage on the
individual stator conductor bars. All of the materials used, and their application, are done in such
a manner as to ensure proper functioning and a reasonable degree of long term reliability of the
winding. The stator winding insulation system is complex and requires a variety of tests to
establish its present condition and expected long term reliability. Therefore, to fully test the
stator winding, so that the best possible determination of the winding condition can be made, it is
desirable to perform both AC and DC tests.
DC tests are generally sensitive to the presence of cracks, moisture, particle contamination or a
general degradation of the electrical creepage path. During DC application, the voltage is divided
according to the DC leakage resistance. Basically, DC is used to test the conductivity of the
insulation system. DC testing has the advantage that it less damaging to the insulation due to the
absence of corona and partial discharges associated with AC.
AC testing on the other hand applies the more realistic electrical stress to the winding, since it
operates AC when in service. When the AC test voltage is applied, it is actually applied across
several dielectric components of the winding insulation, which are effectively in series.

5-90
Therefore, the leakage current must go through each of the dielectrics until it reaches ground
potential. Under AC, the voltage is therefore divided according to the relative permittivity of
each of the dielectric materials.
AC testing is in fact far more searching than DC. In addition to the conducting properties of the
insulation, AC testing is also capable of determining the loss or power factor characteristics and
the dielectric properties. In addition, the mechanical integrity of the insulation can be also be
alluded to by the capacitance characteristics of the winding in terms of insulation de-lamination.
Like with many other issues about testing insulation of large electric machines, experts and
operators have different opinions about which one of the tow tests (DC and/or AC) is more
convenient. Some only prefer DC tests, while other prefer AC testing. Still, others prefer using
both.
5.17.4.2.1 Pre-Testing Requirements
If the stator winding is water cooled, it must be completely dried prior to all testing to obtain
meaningful results. If there is stator cooling water left in the winding it will alter the test results
and give a distorted picture of the insulation condition.
All three phases must be isolated to ensure all testing is carried out on the stator winding only.
This means that each phase should be completely separated at the neutral point and floated from
ground. The line ends of the stator winding should be separated from the Isolated Phase Bus (or
cables, in smaller units) just outside the generator, at the stator terminals.
The generator current transformer windings should be shorted and grounded to avoid induced
high voltage and possible discharge failure of the insulation.
All instrumentation leads should be grounded to also avoid induced high voltage and possible
discharge failure of the insulation.
Before conducting any high-voltage testing of the unit, consult vendor and/or pertinent standards.
5.17.4.2.2 Series Winding Resistance
This test is used to measure the ohms resistance of the copper in each phase of the stator
winding. Given the relatively low DC series resistance of windings of large machines, the
measurement accuracy requires significance to a minimum of 4 decimal places.
The purpose of the test is to detect shorted turns, bad connections, wrong connections and open
circuits. Acceptable test results consist of the three resistance values (one per phase) to be
balanced within a 0.5% error from the average.
The test is very sensitive to differentials of temperature between sections of the winding. The
machine should be at room temperature when the test is performed.

5-91
As with any other electrical test, the results should be compared with original factory data, if
available.
This test can be performed on stator and rotor windings.
5.17.4.2.3 Insulation Resistance (IR)
The purpose of this test is to measure the ohmic resistance between the conductors in each of the
3-phases and ground (i.e. the stator core). This test is generally regarded as an initial test to look
for gross problems with the insulation system, and to ensure further high voltage electrical
testing may relatively safely continue, in terms of danger of failing the insulation.
Normally, the measurements of IR will be in the mega-ohm range for good insulation, after the
winding is subjected to a DC test voltage usually done anywhere from 500 to 5000 V, for one
minute. The minimum acceptable reading by IEEE Standard 43 [4] is (VLL in kV + 1) M. The
test is carried out with a Megger device. However, resistance bridges may also be employed.
The DC test voltage level is usually specified based on: the operating voltage range of the
machine, the particular component of the generator being tested, operators policy and previous
experience, and knowledge of the present condition of the insulation in the machine.
Although the readings obtained will be somewhat voltage-dependent, this dependency becomes
insignificant for machines in which the insulation is dry and in good condition. This is why it is
essential that the stator winding is completely dried before any testing, so that any poor readings
will be due to a real problem, and not residual moisture from the stator cooling water.
The readings are also sensitive to factors like humidity, surface contamination of the coils, and
temperature. Readings should be corrected to a base temperature of 40
o
C by the following:
R (40
o
C) = K * R
measured
(
o
C)
Where K is a temperature-dependent coefficient, which can be obtained from IEEE Std 43 (see
Figure 5-25).
The following equation can be used to obtain K to some degree of accuracy in lieu of the
standard:
K = 0.0635 * exp(0.06895 * T
measurement
in
o
C)
Insulation Resistance tests are performed on both stator and rotor windings, core-end flux
screens, and core-compression or through-bolts as mentioned previously.

5-92

Figure 5-25
IR Versus Temperature (Courtesy of IEEE 2004)

5-93
The insulation between the core-end flux screen and the stator core-end iron ensures that the flux
screen maintains its capability to shield the core-end from axial flux, and keep the resulting
circulating currents within the flux screen, without providing a current path to the core.
The insulation between core-compression bolts and the iron keeps the through-bolts from short-
circulating the insulation between the core laminations. Otherwise, large eddy currents generated
within the core would produce heat and temperatures, which could further damage the inter-
laminar insulation, as well as the insulation of the windings. Figure 5-26 shows typical IR
behavior as a function of time.

Figure 5-26
Polarization Index Dryness Curve (Courtesy of IEEE 2004)

5-94
5.17.4.2.4 Polarization Index (PI)
Insulation resistance is time-dependent as well as being a function of dryness. The amount of
change in the IR measured during the first few minutes depends on the insulation condition, and
the amount of contamination and moisture present. Therefore, when the insulation system is
clean and dry, the IR value tends to increase as the charge is absorbed by the dielectric material
in the insulation. When the insulation is dirty, wet or a gross insulation problem is present, the
charge does not hold and the IR value will not increase, due to constant leakage current at the
problem area. Therefore, the ratio between the resistance reading at 10 minutes and the reading
at 1 minute produces a number or Polarization Index which is essentially used to determine
how clean and dry the winding is (see Figure 5-27).
Class B and F windings tend to show higher PI values than windings made of Class A insulation.
It is also dependent on the existence of a semi-conducting layer.
The recommended minimum PI values are as follows:
Class A insulation: 1.5
Class B insulation: 2.0
Class F insulation: 2.0
The same Megger used for the IR readings should be used to determine the PI. The PI readings
should be done on a per phase basis at the same voltage as the IR test, and can be used as a
go/no-go test before subjecting the machine to subsequent high voltage tests, either AC or DC.
The IR readings for the PI test should also be corrected to 40
o
C as in the IR test. Performing the
high voltage tests on wet insulation may result in unnecessary failure of the insulation.

5-95

Figure 5-27
IR Versus Temperature PI (Courtesy of IEEE 2004)
5.17.4.2.5 Dielectric Absorption During DC Voltage Application
Dielectric absorption current characteristics can be used to measure the aging of the resin binder
in the groundwall insulation. When applying DC voltage to insulation material, a time-dependent
flow of current is established. This current has a constant component, called the conduction
current or leakage current, and a transient component, called the absorption current.

5-96
Absorption current is a function of the polarization of the molecules in the binding material. The
older the binding material, the more polarized it becomes, and the more absorption current flows.
Therefore, this test is best used as a comparison test between the winding condition at different
times, and between similar windings.
Absorption current is also temperature dependent. This fact should be taken into consideration
when performing the test and interpreting the results.
Absorption current is also dependent on the amount of voids in the insulation. The dependence is
inverse, i.e. an increase in the number of voids in the insulation, will tend to reduce the
magnitude of absorption current. The contradictory effects regarding voids density and aging of
the binding material, renders this test difficult to interpretation. It is best when used in
conjunction with other dielectric tests, such as Partial Discharge and Dissipation Factor Tip-Up
tests.
5.17.4.2.6 DC Leakage or Ramped Voltage
The DC leakage or ramped voltage test, is a controlled DC voltage application designed to test
the winding in such a manner as to monitor the DC leakage current, at the same time the DC
voltage is increased. The leakage current is plotted against the DC voltage applied to give early
warning of any impending insulation breakdown. This helps in limiting damage by shutting
down the test prior to a full breakdown occurring (see Figure 5-28).
When applying DC voltage to the winding, a time-dependent flow of current is established. This
current has a constant component, called the conduction or leakage current, and an initial
component, called the charging or absorption current. Therefore, it is advisable to raise the
voltage to the first level of the kV/min. rate, and hold for 10 minutes, to get beyond the charging
phase of the voltage application, and test while dealing primarily with the leakage current. In this
way, charging current influence on the leakage current rate of rise will be minimized.
The final DC test voltage level is generally in the range of 125% to 150% of (V
LL
x 1.7) kV DC
(ANSI Standard C50.10). The value actually chosen between 125% up to 150% of the test
voltage is dependent on the age of the machine insulation, and knowledge of its general
condition.
The ramp rate is selected at 3% of the final test voltage level in kV DC/minute (IEEE Standard
95). The ramp rate usually is in the range of 1.5 to 2 KV per minute.
Generally the ramping portion of the test is automated to allow a steady increase in the voltage.
A DC Hi Pot set with the capability of a timed and steady voltage increase is required. If this is
not possible with the equipment available, then a basic DC Hi Pot set can be used to raise the
voltage in the pre-determined 3% voltage steps, holding each step for 1 minute.

5-97

Figure 5-28
DC Ramp (Courtesy of IEEE 2004)
5.17.4.2.7 DC Hi-Pot
The DC Hi-Pot test is used to ascertain if the winding is capable of sustaining the required rated
voltage levels (without a breakdown of the insulation), with a reasonable degree of assurance for
capability to withstand over-voltages and transients, and maintain an acceptable insulation life.

5-98
The test consists of applying high voltage to the winding (the three phases together, or one at a
time, with the other two grounded) for one minute.
The recommended test voltage level is [(2 x V
LL
+ 1000) x 1.7] kV DC for new windings (ANSI
Standard C50.10).
The recommended test voltage level for field-testing and maintenance purposes is 125% to 150%
of (V
LL
x 1.7) kV DC (ANSI Standard C50.10).
The value actually chosen for the test voltage is dependent on the age of the machine insulation,
knowledge of its general condition, and the specific situation calling for a test.
5.17.4.2.8 AC Hi-Pot
The AC Hi-Pot test is also used to ascertain if the winding is capable of sustaining the required
rated voltage levels (without a breakdown of the insulation), with a reasonable degree of
assurance for capability to withstand over-voltages and transients, and maintain an acceptable
insulation life.
The test consists of applying high voltage to the winding (the three phases together, or one at a
time, with the other two grounded) for one minute.
The recommended test voltage level is (2 x V
LL
+ 1000) kV AC for new windings (ANSI
Standard C50.10).
The recommended test voltage level for field-testing and maintenance purposes is 125% to 150%
of V
LL
kV AC (ANSI Standard C50.10).
The value actually chosen for the test voltage is dependent on the age of the machine insulation,
knowledge of its general condition, and the specific reasons for the calling for a test.
AC testing is generally done at power frequency of 60 Hz but may also be carried out at a low
frequency of 0.1 Hz, which is the accepted industry standard.
Generally the AC Hi-Pot is a pass or fail type of test. However, this is not always the case.
There are often times when arcing can be heard and even seen (see Figure 5-29) and the test can
be stopped until the problem area is repaired. Then retesting may be carried out to prove the
repairs.
Also, testing is usually done on water-cooled windings with the system drained and vacuum
dried before voltage application. However, there are instances where good DC measurements
have been recorded on two phases while one appears grounded, while the winding is technically
wet. In such an instance, AC testing has been done as a next step, but this is a rare occasion. It
is not recommended to proceed with this type of testing unless an expert is present to know how
to handle this type of situation. One of the reasons to do a wet AC test would be when there
appears to be no failure point that can be found and yet the winding will not hold DC voltage and

5-99
internal contamination of the stator winding hoses is suspected. Under dry conditions, the
winding will pass high voltage testing and under wet conditions, the contamination will be
conducting. Depending on the type of contamination and its conductivity, the hoses may glow
under high voltage AC (see Figure 5-30).

Figure 5-29
Stator Hi-Pot Arcing (Courtesy of IEEE 2004)

5-100

Figure 5-30
LKV G5 EE Hoseglow (Courtesy of IEEE 2004)
5.17.4.2.9 Partial Discharge (PD) Off-line Testing
In principle, PD measurements are based on direct measurement of the pulses of high frequency
current discharges created during the occurrence of partial discharges.
Some off-line methods are based in a capacitive link between the whole of the winding and the
measurement equipment. These set-ups allow the measurement of PD activity in whole
windings, or one phase at a time.
To measure the PD activity in smaller sections of the winding, methods based on an
electromagnetic probe or pickup (which is mounted on a hand held electrically insulated stick)
has been developed. One such probe is known as the TVA Probe and is used to traverse the
entire length of a slot in the stator bore to search for localized sources of PD. Therefore, each slot
is probed over its full length.
The partial discharge tests are carried out from voltages below the inception voltage up to rated
voltage.
On-line partial discharge analysis can be performed by modern instrumentation and methods
described in the following sections.

5-101
5.17.4.2.9.1 PD Monitoring by Capacitive Coupling
Partial discharge monitoring by capacitive coupling is generally an on-line test these days, but
off-line measurements are also done on a regular basis. The test setup for off-line capacitive
coupling is generally as shown in Figure 5-31.

Figure 5-31
PD Off-Line Capacitive Coupling (Courtesy of IEEE 2004)
During operation of a generator, the voltage on the stator winding is graded according to the line
to neutral connection. Thus, when an on-line test is performer, the bars near the neutral end of
the machine are not subjected to high voltage, which represents the actual operating condition. In
the off-line test, all stator bars are energized to the level of the test voltage applied and therefore,
all may show PD activity. However, in the off-line test, the effects of vibration and bar forces are
not in play. These issues are important to be taken into consideration when analyzing the test
results and their implication on the condition of the unit.
5.17.4.2.9.2 PD Monitoring by Stator Slot Coupler
The Stator Slot Coupler (SSC) is basically a tuned antenna with two ports. The antenna is
approximately 18 inches (46 cm) long and is embedded in an epoxy/glass laminate with no
conducting surfaces exposed. SSCs are installed under the stator wedges at the line ends of the
stator winding, such that the highest voltage bars are monitored for best PD detection. Since the
SSC is also installed lengthwise in the slot at the core end, its two port characteristic gives it
inherent directional capability.
The problem of noise is virtually eliminated in the SSC. Although the SSC has a very wide
frequency response characteristic that allows it to see almost any signal present in the slot where
it is installed, it also has the characteristic of showing the true pulse shape of these signals. This
gives it a distinct advantage over other methods, which cannot capture the actual nature of the
PD pulses. Since PD pulses occur in the 1 to 5 nanoseconds range and are very distinguishable
with the SSC, the level of PD activity can be more closely defined.

5-102
In addition, dedicated monitoring devices have been devised to measure the PD activity detected
in the SSC. The capability for PD detection using the SSC and its associated monitoring interface
is enhanced to include measurement in terms of the positive and negative characteristic of the
pulses, the number of the pulses, the magnitude of the pulses, the phase relation of the pulses and
the direction of the pulses (i.e. now from the slot or from the endwinding or actually under the
SSC itself at the end of the slot).
The other advantage of the SSC is that once it is installed, measurements may be taken at any
time without the need for exposing live portions of the generator bus-work, for the purpose of
making connections to the test equipment.
5.17.4.2.9.3 Corona Probing for PD
Partial discharge tests in general determine only the relative condition of the stator winding from
the generator terminals. They do not locate specific sites of deterioration or damage in the
winding. To do this, the winding must be locally scanned with special probes designed to detect
localized sources of PD, while the winding is energized to the level of line-to-neutral voltage.
There are a couple of variations of probe types, one based on radio frequency noise and the other
on acoustical noise. (SSCs do provide some information about the location of the PD activity.
The more SSCs installed in a particular winding, the higher the accuracy in determining the
location of the offending bar).
The TVA Probe gets its name from the Tennessee Valley Authority where it was first
popularized. It is based on an earlier Westinghouse probe design, sensitive to RF signals
produced by PD in the winding. It functions by picking up the RF energy radiated from active
PD sites in the winding. The greater the PD, the greater the RF energy produced. The tip of the
TVA probe employs a loop antenna similar to that used in an AM radio. The TVA antenna is
tuned to about 5 MHz so that it is sensitive to near-field RF discharge. The output of the antenna
is directed by a co-axial cable to a tuned RF amplifier and a peak-reading ammeter that is
sensitive to peak PD pulses. The closer the antenna is brought to an RF (or PD) source, the
higher the output on the meter.
The Ultrasonic Probe functions based on acoustic noise produced by localized PD sites. The
noise is similar to a crackling sound that one might hear when next to a high voltage overhead
transmission line on a wet day. This noise is loudest in the ultrasonic frequency range around 40
kHz. A high directional microphone, sensitive to the 40 kHz noise, is used to locate the site of
the PD discharges. Given that ultrasonic noise does not easily penetrate insulation, the ultrasonic
probe test is primarily sensitive to surface PD, i.e. the sites of slot discharge and surface
endwinding PD.
5.17.4.2.10 Capacitance Measurements
Capacitance measurements are also a method of measurement by which the quality of the
insulation can be indicated. The measurements are, of course, done with AC voltage, and
generally on a per phase basis.

5-103
Each phase of the stator winding is energized to line-to-neutral voltage, while the other two
phases are grounded. The power factor of the winding is measured with a capacitance bridge to
determine the value of the per-phase winding capacitance. Comparison of the measured
capacitance to the factory measured values, and then successive capacitance readings, can aid in
showing deterioration of the ground-wall insulation over time.
5.17.4.2.11 Dissipation/Power Factor Testing
The dissipation factor (or tan ) is an AC test used to measure the bulk quality of the groundwall
insulation, by measuring the dielectric loss (primarily due to partial discharges) per unit of
volume of the insulation.
Note: (Dissipation Factor) DF = tan
(Insulation Power Factor) IPF = DF . = sin
1 + ( DF )
2

Results are generally dependent on the type of the dielectric material in the insulation system. An
increase in DF over the life of the winding can be attributed to an increase in internal voids, de-
laminations, and/or increased slot-coil contact resistance (i.e. deterioration of the semi-
conducting paint in the slot).
The readings are a dimensionless quantity expressed in percent. The absolute values obtained
are, again, a function of the type of insulation system being measured and are also directly
affected by the temperature of the winding. Therefore, it is important that insulation power factor
readings be taken at similar temperatures. The results are even more useful however, in relative
terms by comparison of present readings to past readings. Successive measurements provide a
scale of the deterioration rate of the insulation system over time.
Therefore, when using dissipation factor as a function of time, it is important to maintain
constant conditions during testing. DF readings are directly affected by the temperature of the
winding and are also a function of the applied voltage. Therefore, comparisons with previous
readings should be made on tests done at similar temperatures and the same voltage levels.
Since dissipation factor readings are somewhat void dependent, the dissipation/insulation power
factor ratio will increase with an increase in the amount of voids present in the insulation. This
phenomenon is the base of the DF/IPF Tip-Up test.
5.17.4.2.12 Dissipation/Power Factor Tip-Up Test
The Dissipation Factor Tip-Up or tan test looks at the void content in the insulation. That is to
say, the dissipation factor will increase with an increase in the amount of voids or de-lamination
present in the insulation. In addition, it also provides information on other ionizing losses in the
form of partial and slot discharges.

5-104
The test is done by taking DF (or insulation power factor) measurements at different voltages. A
set of readings is therefore obtained, which forms an ascending curve. A fast change of
insulation power factor with increasing voltage tends to indicate a coil with many voids. The test
is based on the fact that ionization, both internal and external to the insulation is voltage
dependent.
The test is done generally at 25 and 100 percent of the rated phase to neutral voltage. The Tip-Up
value is the DF measurement at the higher voltage, minus the DF measurement at the lower
voltage (IEEE Standard 286). Good readings for an epoxy/mica system, indicating minimal void
content in the insulation, are typically less than 1%. Good readings for an asphalt system are
generally in the 3% range (see Figure 5-32).
This test will give a good evaluation of the winding as a group, however any bad coil that
deviates greatly from the rest will not be discerned by this test. To ferret out individual bars,
which may exhibit higher discharges, a Partial Discharge test can be done with the addition of
manual probing for the location of the discharges if high levels are found to exist.

Figure 5-32
Dissipation Factor Tip-Up (Courtesy of IEEE 2004)

5-105
5.17.4.3 Generator Rotor Electrical Testing
5.17.4.3.1 Winding Resistance
The field-winding series-resistance is measured to determine the ohms resistance of the total
copper winding in the rotor.
Given the relatively low DC series resistance of windings of large machines, the measurement
accuracy requires significance to a minimum of 4 decimal places.
The purpose of the test is to detect shorted turns, bad connections, wrong connections and open
circuits. The machine should be at room temperature when the test is performed.
As with most other electrical test, the results should be compared with original factory data, if
available.
5.17.4.3.2 Insulation Resistance (IR)
The purpose of the IR test is to measure the ohmic resistance between the total rotor winding
insulation and ground (i.e. the rotor forging). This test is generally regarded as an initial test to
look for gross problems with the insulation system, and to ensure further high voltage electrical
testing may (relatively) safely continue, in terms of danger of failing the insulation.
Normally, the measurements of IR will be in the mega-ohm range for good insulation, after the
winding is subjected to a DC test voltage usually done anywhere from 500 to 1000 V, for one
minute. The minimum acceptable reading by IEEE Standard 43 is (V
f
in kV + 1) M. The test is
carried out with a Megger device.
The DC test voltage level is usually specified based on: the operating and field forcing voltage of
the rotor, utility policy and previous experience, and knowledge of the present condition of the
insulation in the rotor.
It is essential that the rotor winding be completely dried before any testing, so that any poor
readings will be due to a real problem and not residual moisture.
The readings are also sensitive to factors like humidity, surface contamination of the coils, and
temperature. Readings should be corrected to a base temperature of 40
o
C (see Figure 5-26).
All of the above also applies to the rotor bore copper and collector rings.
5.17.4.3.3 Polarization Index (PI)
Insulation resistance is time dependent as well as being a function of dryness for rotor insulation,
just as in the stator. The amount of change in the IR measured during the first few minutes
depends on the insulation condition, and the amount of contamination and moisture present.

5-106
Therefore, when the insulation system is clean and dry, the IR value tends to increase as the
dielectric material in the insulation absorbs the charge. When the insulation is dirty, wet or a
gross insulation problem is present, the charge does not hold and the IR value will not increase,
due to constant leakage current at the problem area. Thus, the ratio between the resistance
reading at 10 minutes and the reading at 1 minute produces a number or Polarization Index
which is essentially used to determine how clean and dry the winding is.
The recommended minimum PI values are as follows:
Class B insulation: 2.0
Class F insulation: 2.0
The same Megger used for the IR readings should be used to determine the PI. The PI readings
should be done at the same voltage as the IR test and can be used as a go/no-go test before
subjecting the rotor to subsequent high voltage tests, either AC or DC. The IR readings for the PI
test should also be corrected to 40
o
C as in the IR test (see Figure 5-25). Performing the high
voltage tests on wet insulation may result in unnecessary failure of the insulation.
5.17.4.3.4 DC Hi-Pot
The DC Hi-Pot test is used to ascertain if the winding is capable of sustaining the required rated
voltage levels (without a breakdown of the insulation), with a reasonable degree of assurance for
capability to withstand over-voltages and transients, and maintain an acceptable insulation life.
The test consists of applying high voltage to the rotor winding for one minute.
DC Hi-Pot testing on rotor windings is normally done between 1500 V up to approximately 10
times the rated field voltage.
5.17.4.3.5 AC Hi-Pot
The AC Hi-Pot test is also used to ascertain if the winding is capable of sustaining the required
rated voltage levels (without a breakdown of the insulation) with a reasonable degree of
assurance for capability to withstand over-voltages and transients, and maintain an acceptable
insulation life.
The test consists of applying AC high voltage to the rotor winding for one minute.
AC Hi-Pot testing on rotor windings is also normally done at to 10 times the rated field voltage
at line frequency of 60 Hz.
5.17.4.3.6 Shorted Turns Detection - General
Shorted turns in rotor windings are associated with turn-to-turn shorts on the copper winding, as
opposed to turn to ground faults.

5-107
Rotor winding shorted turns, or inter-turn shorts can occur from: an electrical break down of the
inter-turn insulation, mechanical damage to the inter-turn insulation allowing adjacent turn to
turn contact, or contamination in the slot which allows leakage currents between turns. A project
was implemented by EPRI that developed a traveling wave monitoring technique that can both
detect and determine the location of shorted windings on-line without the installation of a
sensing coil. The report On-Line Detection of Shorts in Generator Field Windings, TR-114016,
[45] describes this project.
When shorted turns occur, the total ampere-turns produced by the rotor are reduced, since the
effective number of turns has been reduced by the number of turns shorted. The result is an
increase in required field current input to the rotor to maintain the same load point, and an
increase in rotor winding temperature.
At the location of the short, there is a high probability of localized heating of the copper winding
and arcing damage to the insulation between the turns. This type of damage can propagate and
worsen the fault, such that more turns are affected, or the ground-wall insulation becomes
damaged and a rotor winding ground occurs.
One of the most noticeable effects of shorted turns is increased rotor vibration due to thermal
effects. When a short on one pole of the rotor occurs, a condition of unequal heating in the rotor
winding will exist between poles. The unequal heating may cause bowing of the rotor, and hence
vibration. The extent and location of the shorted turns and the heating produced will govern the
magnitude of the vibrations produced.
One general relationship between the location of the shorted turn/turns and vibration is:
Lower vibration is generally experienced when the short is on the Q-axis.
Higher vibration is generally experienced when the short is nearer the pole or D-axis.
Stated differently, the rotor is more prone to vibration due to shorted turns, if the shorts are
located in the small coils rather than in the large coils. The small coils being those located
closer to the pole-faces.
The reasoning for the above is the lack of symmetry with faults nearer the pole face. There is an
inherent unbalance in the geometry and heating effect on the rotor forging.
Off-line methods for detecting shorted turns include winding impedance measurements as the
rotor speed is varied from zero to rated speed, and RSO (Recurrent Surge Oscillation) tests,
based on the principle of time domain reflectometry. In addition, a short of significant magnitude
may be identified by producing an Open Circuit Saturation Curve, and comparing it to the design
OC Saturation Curve. If the field current required to produce rated terminal voltage has increased
from the original design curve, then a short would be likely present. The number of shorted turns
may be identified by the ratio of the new field current value over the design field current value.
All of the above methods of identifying shorted turns are prone to error and only indicate that a
short exists. They do little to help locate which slot the short is in and require special conditions

5-108
for collecting the data or for testing. To better identify shorted turns, and to employ a method
that works on-line, the search coil method has been perfected. Each OEM has their own version
of a search coil method, but all work essentially in the same manner.
5.17.4.3.7 Shorted Turns Detection by Recurrent Surge Oscillation (RSO)
In the RSO method, a low voltage (a few volts) high-frequency (kHz range) surge wave is
injected at each one of the collector rings. The two signals are then compared to determine if the
same waveform is observed at each collector ring. If the waveform is identical, then no shorts are
present. Variations in the two waveforms would indicate shorts to be present. This method is
based on the principle of time domain reflectometry.
This also has the advantage of allowing the rotor to be spun as well, while doing the
measurements, to determine if the shorts are also speed sensitive. This test has the advantage of
taking the mechanical loading effects into consideration. In the spinning RSO, there may be
shorts that reveal themselves, which are not seen when the rotor is at rest, because at rest there is
no mechanical load on the winding turns, other than their own weight.
Because the RSO also works on a time of flight principle, the location of the coil number where
the shorts are, as well as which pole, are also somewhat discernable by this method. Shorts
nearer the sliprings show up as blips in the RSO pulse nearer the left side of the traces. And for
the number of turns shorted at the particular location (i.e. the particular coil), the magnitude of
the blip increases as more turns are shorted.
In the at-rest test, the RSO is connected directly to the winding via the collector rings. Thus,
only the winding impedance is seen by the high frequency, low voltage pulses sent by the RSO.
In the spinning RSO test, to accommodate the moving rotor, the leads of the RSO must be
connected to the brush rigging, and the connection to the winding is then implemented via the
brushes-collector-rings. However, with this connection also anything connected towards the
excitation equipment is seen by the pulses (e.g.: leads, contacts, field breaker, field resistor,
excitation equipment). The principle of operation of the RSO is comparing the pulses inserted in
each polarity terminal of the winding, and their reflections. The test is extremely sensitive to any
asymmetry on the path of the pulses. From a point of view of the wave-impedance seen by the
high-frequency pulses, the field winding is by nature very symmetrical, but the excitation system
is anything but that. Therefore, in order to obtain any significant signature on the condition of the
field-winding, the noise originating in the path towards the excitation must be reduced as much
as possible. This is achieved by opening the excitation leads at a convenient location between the
excitation system and the brush rigging. After the leads are open, only cables of almost exactly
equal length are left connected to the brush rigging. The effect introduced by these cables is
generally negligible.
Figures 5-33 to 5-39 depict samples of RSO test-readings taken on a 2-pole turbo-generator
rotor.

5-109

Figure 5-33
NO Shorted Turns Traces Superimposed (Courtesy of IEEE 2004)

Figure 5-34
NO Shorted Turns Traces Separated (Courtesy of IEEE 2004)

Figure 5-35
NO Shorted Turns Traces Summed (Courtesy of IEEE 2004)

5-110

Figure 5-36
RSO Single-Shorted Turn Dual Superimposed Trace (Courtesy of IEEE 2004)

Figure 5-37
RSO Single-Shorted Turn Difference Trace (Courtesy of IEEE 2004)

Figure 5-38
RSO Dual-Trace Multi-Shorts (Courtesy of IEEE 2004)

5-111

Figure 5-39
RSO Difference Trace Multi-Shorts (Courtesy of IEEE 2004)
5.17.4.3.8 Shorted Turns Detection by Open Circuit Test
Producing an Open Circuit Saturation Curve, and comparing it to the design Open Circuit
Saturation Curve may identify a shorted turn condition of significant magnitude. If the field
current required to produce rated terminal voltage has increased from the original design curve,
then a short would be likely present (see Figure 5-40).
The number of shorted turns may be identified by the ratio of the new field current value over the
design field current value. However, due to the many number of turns in a typical rotor winding,
the changes in open circuit voltage due to a single shorted turn in the field winding may go
unnoticed since the measurement is too small for a positive identification.
The open circuit stator voltage versus field current characteristics can be measured in all
synchronous machines. This curve, taken with the machine spinning at synchronous speed, is
unique for each machine.
In principle, this test allows detecting shorted turns in brushless machines, where RSO
techniques are too difficult to perform, and always entails partial disconnection of the rotor leads.

5-112

Figure 5-40
STD by Open Circuit (Courtesy of IEEE 2004)
5.17.4.3.9 Shorted Turns Detection by Winding Impedance
Impedance measurements while the machine is decelerating or accelerating can also be used to
detect a speed dependent shorted turn.
Any sudden change in the readings may indicate a shorted turn being activated at that speed.
A gradual change of impedance of more than 10% may also indicate a solid short (Figure 5-41).

5-113

Figure 5-41
STD by Impedance (Courtesy of IEEE 2004)
5.17.4.3.10 Shorted Turns Detection by Low Voltage DC or Volt Drop
This test is designed to determine the existence of shorted turns in the rotor winding. The test is
entirely different when performed on salient pole rotors than in cylindrical (round) rotors.
In salient pole machines, a pole drop test is done. In this test, the resistance across each
individual pole is measured by the V/I method, i.e., applying a voltage of around 100 to 120
volts, 60 Hz, to the entire winding, and then measuring the voltage drop across each pole. A pole
with lower voltage drop will indicate a shorted turn or a number of shorted turns.
In either salient pole or round rotor machines, the shorted turns are often speed dependent (i.e.
they might disappear at standstill). To partially offset this phenomenon, it is recommended to
repeat the pole drop test a few times with the rotor at several angles. The gravity forces exerted
on the vertically located poles may activate some short circuits between turns, which might not
show up when in, or close to, the horizontal position.
In round rotors the individual windings are generally not accessible, unless the retaining-rings
are removed. Therefore, detection of shorted turns in not always possible by this method.
5.17.4.3.11 Shorted Turns Detection by Low Voltage AC or C Core Test
A C shaped, wound core is required to carry out this test, together with a voltmeter, wattmeter
and single phase power supply (see Figure 5-42).
Shorted turns are detected by sharp changes in the direction of wattmeter readings (see Figure 5-
43).

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In rotors with damper windings, or with the wedges short-circuited at the ends to form a damper
winding, these have to be disconnected at the ends. This operation requires removal of the
retaining-rings.

Figure 5-42
C-Core 1 (Courtesy of IEEE 2004)

5-115

Figure 5-43
C-Core 2 (Courtesy of IEEE 2004)
5.17.4.3.12 Shorted Turns Detection by Shorted Turns Detector (Flux Probe)
The flux probe is actually a search coil mounted on the stator core by various methods, but
located strategically in the air gap. The search coil looks at the variation in magnetic field
produced in the air gap by the rotor as it spins. The energized rotor winding and the slotted effect
of the winding arc cause a sinusoidal signal to be produced in the winding face of the rotor. The
pole face on the other hand has no winding and the signal is more flat since the variation in
magnetic field is minimal.
The magnitude of the sinusoidal peaks in the winding face is dependent on the ampere-turns
produced by the winding in the various slots. If there is a short in a slot, then the peak of the
signal for that affected slot will be reduced. The reduction will be dependent on the magnitude of
the short. Therefore, as well as knowing which slot the short is in, an estimate of the number of
shorted turns can be made fairly accurately.
Problems due to saturation effects at full load can occur in analyzing the data and most OEMs
now have a dedicated monitor connected to the flux probe to automate the analysis process. This
allows the flux probe and monitor to act as stand-alone sensor to alarm when a short turn is
detected and notify the operator for investigation.

5-116
Probably the most effective method for the detection of shorted turns in solid rotors is the flux
probe method. This device maps the flux of the machine as it rotates, indicating possible shorts
as changes in the measured waveform. Its main advantage is that it works with the rotor on-line,
capturing the speed dependent shorts. Its main disadvantages are the expertise required in
analyzing the recorded waveforms, and the fact that the machine has to be de-energized and de-
gassed for the installation of both core-mounted and wedge-mounted types of probes. New
commercially available units intended for on-line continuous operation, include software, which
analyses the waveform and alerts to a possible shorted-turn condition.
5.17.4.3.13 Field Winding Ground Detection by Split Voltage Test
The split voltage test is used locate rotor grounds as a percentage through the field winding.
For this test to be effective, the resistance to ground of the fault must be less than 5% of the
balance of the rotor insulation, and the voltmeter must have high input impedance, when
compared to the ground fault. The retaining-rings should also be left on in case the ground is to
one of the rings.
The test is done by applying up to 150 Volts DC, ungrounded, across the sliprings. A
measurement of DC voltage is then taken from the rotor coupling at the turbine end of the
forging to one of the collector rings. The measurement is then made from the other collector ring
and the same location on the rotor coupling at the turbine end. In this way, the two voltage
measurements can be compared to estimate how far into the winding the ground has occurred. If
the two measurements are equal, the rotor ground fault should be found in the middle of the
winding. If there is less than 2% difference between the two readings, then the ground could
possibly be at the collector rings.
This test is very useful in helping to determine how much dismantling is required to find the
ground. Depending on where the ground is located, it can obviously make a big difference in the
time expended to find the fault (see Figure 5-44).

5-117

Figure 5-44
Rotor Ground Split Voltage (Courtesy of IEEE 2004)
5.17.4.3.14 Field Ground Detection by Current Through Forging Test
The current through forging test is another test used to locate rotor-winding grounds. In this
particular application, the test is used to locate the actual axial position of the ground.
The retaining-rings should be left on the rotor in case the ground is at one of the rings.
For this test, a DC current of about 500 amps is put through the forging from the tip of the
forging at the slipring end to the coupling at the other end. A DC ammeter is used to look for the
ground position. This is done by attaching one lead of the ammeter to the most outboard slipring,
and then using the other lead to probe along the axial length of the rotor forging. At the point
where the ground is, the current should reduce to zero or if the current is not zero but only very
low, then there will be a polarity change at the ground location (see Figure 5-45).

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Figure 5-45
Rotor Ground Current Through Forging (Courtesy of IEEE 2004)
5.17.4.3.15 Shaft Voltage and Grounding
During operation, voltage may rise on the generator rotor shaft, unless the shaft is grounded. The
sources of shaft voltage are well established and identified as: voltage from the excitation system
due to unbalanced capacitive coupling, electrostatic voltage from the turbine due to charged
water droplets impacting the blades, asymmetric voltage from unsymmetrical stator core
stacking, and homopolar voltage from shaft magnetization. If these voltages are not drained to
ground they will rise and break down the various oil films at the bearings, hydrogen seals,
turning gear, thrust bearing, etc. The result will be current discharges and electrical pitting of the
critical running surfaces of these components. Mechanical failure may then follow.
Inadequate grounding of the rotor will also allow voltage to build on the generator rotor shaft.
Inadequate grounding may be due to: a problem with the shaft grounding brushes from wear
(requiring replacement brushes) or a problem with the associated shaft grounding circuitry if a
monitoring circuit is provided.
High shaft voltages can also be caused by severe local core faults of large magnitude, which
impress voltages back on the shaft from long shorts across the core.
Protection against shaft voltage buildup and current discharges is provided in the form of a shaft-
grounding device, generally located on the turbine end of the generator rotor shaft. The most
common grounding devices consist of a carbon brush or copper braid, with one end riding on the
rotor shaft and the other connected to ground.

5-119
Shaft voltage and current monitoring schemes are also provided in many cases to detect the
actual shaft voltage level and current flow through the shaft grounding brushes. This has the
advantage of providing warning when the shaft grounding system is no longer functioning
properly and requires maintenance. There are numerous monitoring schemes available and each
OEM generally has its own system provided with the TG set when purchased. For older
machines with only grounding and no monitoring, a monitoring system can usually be retrofit to
the existing ground brushes. The OEM should be consulted when upgrading the shaft
monitoring.
5.18 Excitation System
The primary purpose of the excitation system is to provide excitation to the main generator. The
main components of any main generator excitation system are: a power supply, a voltage
regulator, and a generator field. The power supply, which can be electrical or mechanical,
provides energy to drive the excitation. The electrical supply can be either a transformer taking
power from the generator bus or a station auxiliary bus feeding a motor generator set exciter. The
main generator field will convert the current supplied by the excitation system into a magnetic
field. The lines of magnetic flux from the rotating generator field cut through the stator-mounted
armature winding and induce an ac voltage in the windings. To control the current supplied to
the generator field, a voltage regulator is used. The control of the field may be direct or indirect.
An indirect approach controls the field current, and a direct approach controls the actual
generator field current.
There are other components in addition to the three mentioned above; they are discussed in the
EPRI report Tools to Optimize Maintenance of Generator Excitation System, Voltage Regulator,
and Field Ground Protection, 1004556 [46]. This report was developed because the cost of lost
generation can greatly exceed the cost of repairing the excitation system. A low-cost high-benefit
ratio is needed to maintain and improve reliability and availability with maintenance budgets the
way they are in a plant provided will help plants benefit economically by using appropriate
levels of PdM and PM tasks through equipment upgrades.
For more information on generators, see the EPRI Power Plant Electrical Reference Series:
Volume 1, Electrical Generators, EL-5036-V1 [47]. Each of the volumes in this series provides
comprehensive and practical information regarding electric power apparatus and electrical
phenomena. Volume 1 presents various excitation systems and their effects on generation
operation for overexcited and underexcited field conditions. It also describes the basic
construction of generators and information concerning the units.
An EPRI report to be issued in January 2006, Excitation System Retrofit and Replacement-
Lessons Learned, 1011675, [60] will provide guidelines on avoiding technical and project
management mistakes in the procurement and retrofit process. This guide will also document the
best practices in replacing excitation systems in hydro, fossil, and nuclear plants. A generic
specification will be published as part of the guide.

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5.19 Using Data on Condition Assessment to Assess Risk of In-Service
Failure
As maintenance intervals increase, parts remain in service for longer periods, and the chances for
inspection to reveal forms of damage increase. The data obtained on the condition of parts in the
turbine or generator may be assessed either deterministically or probabilistically. In either
approach, the basic objective is to calibrate the significance of wear or damage, as characterized
by the type of NDE test, the strengths and limitations of which have been previously reviewed.
A deterministic approach produces a result (in terms of time or cycles) that is subjective to the
users selection of discrete input or factors. A probabilistic approach relies on statistical
distributions to describe these same factors and, by their random combination, estimates the
chances of a failure over the same scale of time or cycles. Examples of each are illustrated in
Volumes 6 and 7 to guide the inspection and replacement of HP, IP, and LP blades
Each approach has merits. A deterministic assessment using NDE data may weigh how much
conservatism or factor of safety exists for a given component for a consistently applied operating
scenario. It can identify where the weakest point occurs in a structure, which will have the least
amount of tolerance to damage. For components where there is a vibratory stress imposed on a
steady load (like rotating blades), it can be used to predict the point at which high-cycle fatigue
will assume control of crack growth, leading to fracture.
A probabilistic approach recognizes that the real world involves uncertainties: for example,
variation between parts, the accuracy of different NDE techniques, the inherent variability in
tolerances, material properties, and the operating stresses that occur within a part. It is generally
a more valid method for weighing the options of run, repair, or replace that are faced by a
maintenance engineer when inspection reveals damage that can be tolerated for a limited period.
The fundamentals in a risk assessment are summarized as follows:
Every component has inherent strength, selected by design to withstand an expected range of
stress.
Conventional remaining life formulas use discrete terms or values to represent properties.
Design formulas often include factors of safety.
In practice, both are random quantities. If applied in the life prediction formulation, the
results generally produce a probability distribution as shown in Figure 5-46, where failure
versus no failure is defined by the limit state function.
The population to the right of the limit state function has a low risk of failure.

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Figure 5-46
Example of a Probability Distribution and Limit State Function
Component life is evaluated in two ways; (1) the number of cycles or time to initiate cracks,
and/or (2) the remaining cycles or time for cracks to propagate to their critical size. As noted, if
there is a dynamic stress present, then this needs to be factored into the assessment.
In a probabilistic treatment of NDE data, each mechanism is evaluated using the same basic
approach. As shown in Figure 5-47, results are produced by first coupling material properties
(obtained from published specimen tests results) with field measurements (obtained during the
outage). The operating history is represented in terms of start-stop cycles, hours in service or
years of service, depending upon the type of damage mechanism that is being evaluated. For
example, low-cycle fatigue or stress corrosion cracking would be evaluated on a scale of start-
stop cycles or years of service, whereas creep would be based on hours in service at high
temperature. High-cycle fatigue life is generally measured in hours or days, particularly when
dealing with turbine blades.

5-122

Figure 5-47
Basic Elements of a Probabilistic Analysis
In any assessment, stress is typically the most critical factor that is unknown to the operator.
Unfortunately, until faced with a problem, many operators do not learn that it is often difficult or
impossible to obtain stress from the designer and that independent analysis requires dimensional
details from the component and time to perform the calculations. It is therefore becoming
standard practice among many plants to reverse-engineer parts, such as blades, that they expect
to replace or to maintain spares even though they may still rely on the OEM as a supplier. With
this data in hand, the simulation is performed in advance of the outage so that the distribution of
stress throughout the component is available prior to the outage.
When each of the factors has been described, a Monte Carlo simulation is performed, which
essentially means that the input factors are randomly combined within the selected life
consumption formula. NDE data may be processed directly when it is available. Prior to an
outage, incremental ranges of indication/crack sizes can be processed. These results are plotted
either on a log scale or linear scale as a family of curves to show the relative change in risk that
occurs as the size of an indication is increased and refined as necessary when actual data are
taken.

5-123
To illustrate this approach and its application in condition assessment, assume that the previously
mentioned technique in remote optical examination of the first row HP buckets was performed
during a boiler inspection. A noticeable degree of solid particle erosion on the leading and/or
trailing edges of the blades was identified. To make a quick determination of the risks involved
in running the row in its present condition, a family of probability curves was produced in
advance of the inspection
As shown in Figure 5-48, these individual curves relate the risk of a failure to incremental notch
sizes of 50350 mils (1.278.89 mm). They are based on stress results obtained from a finite
element analysis, using an erosion rate that was determined from the inspection records prior to
when notches became visibly apparent. A hypothetical distribution of NDE results was applied to
produce the initial set of curves that was easy to update if necessary when the actual results
became available.

Figure 5-48
Example of SPE Inspection Criteria Using Series of Probability of Failure Curves
Inspection revealed no cracks, but random patterns of notch wear ranged from 90 to 225 mils
(2.3 to 5.7 mm) on the trailing edge. The maximum size notch of 225 mils (5.7 mm) measured
after six years is plotted to show the present status of the row. The change in probability is
reflected for each subsequent year of continued operation, extended to the next six-year interval.
In the example, the probabilities are also categorized using a hazard risk assessment
classification matrix originally produced for the Department of Defense (MIL-STD-882C

5-124
Military Standard System Safety Program Requirements,) [48]. This classification can further
facilitate the interpretation of results, beyond a comparison in the relative change in odds.
When reflected in this manner, it quickly becomes apparent that the operator has a powerful tool
by which the NDE data reflecting the present condition of the component can be assessed and
extrapolated to support a run, repair, or replacement strategy. If combined with the costs of doing
the maintenance versus deferring the maintenance, the financial outcome can further assist in
identifying what the optimum time would be to replace the damaged blades.
The following is noted regarding risk assessment as it relates to turbine-generators:
1. Many commercially available programs have evolved to the point where it is not the
mathematics that limits the effectiveness or value of probabilistic applications.
2. The most important ingredient in any assessment is a fundamental understanding of the
damage and/or failure process that is being evaluated. The probabilistic model needs to focus
only on those factors that are relevant.
3. Any risk assessment should focus on individual types or forms of damage, rather than trying
to treat all potential contributors/mechanisms together. The types of damage that affect
turbine-generator components are varied, may occur at different times within the start-stop
cycle, and affect different locations on the component.
4. A well-planned model should be capable of running millions of studies in a matter of
minutes. This can allow the operator to consider what if scenarios in which the input
parameters can be varied to test the sensitivity of the projected risk with regard to key
assumptions.
5. Since the approach is meant to be component specific, valid stress results must be available
as input to the probabilistic model. These results should be derived from finite element
analysis, not design formulas that tend to approximate and/or include factors that do not
reflect the stress field in regions of concentration (where damage naturally tends to form). A
competently performed analysis should be able to produce very reasonable values of stress as
input to the model, that is, with a minimum amount of uncertainty.
6. Most turbine-generator components rely on conventional materials that are well understood
in terms of their mechanical behavior and for which there is ample published information to
develop a statistical basis for input to the model. As more data are used in the model, the
degree of uncertainty associated with this key parameter is reduced. It is important, however,
not to mix data taken from different alloys or test conditions, but to segregate the information
appropriately.
7. In terms of affecting the projected risks, the greatest source of uncertainty is often associated
with the NDE data and how it is characterized. As a rule of thumb, the uncertainty increases
and confidence decreases as the size of the indication approaches the detection limits of the
sensor.

5-125
8. At present, most sensors cannot accurately characterize indications with any degree of
certainty below 3050 mils (0.7621.27 mm). To compensate for this, many risk analyses
presume damage exists of a magnitude just below this detectable threshold. It should be
noted, however, that for some mechanisms (SCC and LCF), this assumption might represent
a significant acceleration in the actual rate of crack formation and growth and thereby
artificially increase the projected risk of failure. This is particularly true if the damage is
occurring in regions of low stress.
The last point is worth some further discussion. Figure 5-49 represents an example published by
an OEM [49] in which test indications obtained by UT were compared via destructive analysis.
The plot shows the ratio of measured sizes, based on UT, versus actual sizes. The range of scatter
reflects the increased statistical uncertainty that would be introduced if used as input to a
probabilistic analysis. The statistical uncertainty becomes more notable as the cracks approach
the detection limits of the NDE technology. For application in a risk assessment, it is therefore
important to scrutinize data obtained on the condition of a part to ensure that it is a valid
representation of its actual condition.

Figure 5-49
Ratio of Actual Crack Sizes to Measured Crack Sizes

5-126
Additional information is provided in Volumes 6 and 7, the EPRI report Steam Turbine Disk
Brittle Failure Influencing Parameters and Probabilistic Analysis Demonstration, 1003264
[50]. The report describes a methodology for assessing the probability of disk brittle failure due
to stress corrosion cracking. The probabilistic method features a finite-element-based approach
to calculate stress intensity as a function of crack length for arbitrary crack geometries. The
importance of key factors governing the probability of failure is demonstrated through a
parametric study.

6-1
6
OIL FLUSHING
Oil flushing often represents a significant period of critical path time. The information presented
within this guideline is primarily designed to identify and describe methods or approaches that
have been used to perform these operations effectively. Methods, tools, and practices that can
accelerate the flushing procedure are discussed for various systems found on different types of
units. Practical approaches or modifications to present systems that would allow bearings to be
isolated and drained on an individual basis are also discussed.
This section of the guidelines identifies, reviews, and compiles practices and techniques that are
normally involved or should be undertaken during the flushing and replacement of the turbine-
generator lubricants.
6.1 Preparations and Precautions for Flushing the System
Because the turbine lube oil is often contaminated during maintenance inspections, the oil system
must normally be flushed. To flush the turbine lube oil system, the oil velocity must be
increased, and the oil must be heated, cooled, and filtered so that contaminants can be removed
from the system. The following information describes the necessary changes that must be made
before the start of a turbine lube oil flush.
1. At the lube oil reservoir, perform the following activities before flushing:
a. Drain and clean the lube oil reservoir.
b. Remove and clean the oil cooler tube bundles.
c. Install one clean oil cooler tube bundle in the cooler.
d. Make provisions to heat and cool the oil in the oil cooler with the tube bundle installed.
e. Set the oil cooler transfer valve to the cooler with the bundle installed.
f. Install a fine mesh screen on the bayonet screens in the return oil sump in the reservoir.
g. Fill the lube oil reservoir with clean oil.
h. Make provisions to monitor the electrical loads on the lube oil pump motor during the
flush.

Oil Flushing
6-2
i. On units with bearing oil relief valves, increase their setting so that they do not open
during the flush.
j. Clean and check all reservoir door seals.
k. On units with temporary oil filtering skids, connect the skid to the reservoir, install new
filtration cartridges, and make the appropriate electrical connections.
2. At all steam control valves for mechanical hydraulic control (MHC) units: (stop, throttle,
control, governor, reheat stop, and intercept), perform the following activities before
flushing:
a. Disconnect the oil feed and drain lines to the servomotors.
b. Install bypass jumpers from the oil feed line to the oil drain line.
c. Install blanks on the servomotors where the oil lines were disconnected.
3. At the front pedestals, perform the following activities before flushing:
a. Clean the interior of the front pedestal.
b. Install a bypass jumper on the journal bearing (feed to drain) with the valve in the line.
c. Install bypass jumpers on any mechanical components in the front pedestal, for example,
gear feed lines, zero speed switches, and safety bearing feed lines.
d. Install the pedestal cover.
4. At the journal and thrust bearings, perform the following activities before flushing:
a. Install bypass jumpers on the bearing (feed to drain) with the valve in the line.
b. Remove the strainer/orifices from the oil feed lines.
c. Label the strainer/orifices and seal in plastic bags.
d. Clean all bearing pedestals and install the pedestal covers.
5. At the thrust bearing wear detector, install bypass jumpers on the thrust bearing wear detector
(feed to drain).
6. At the turning gear, install a bypass jumper on the turning gear (feed to drain).
7. At the generator, perform the following activities:
a. Install blanks in the hydrogen seal feed and drain the line connections to the end bells.
b. Install jumpers in the hydrogen seal (feed to drain) lines with the valve in line.

Oil Flushing
6-3
c. Remove the bearing oil feed line to the end bell, and cover the ends with plastic.
d. Install a bypass jumper on the bearing (feed to drain) with the valve in line.
8. At the exciter, perform the following activities:
a. Remove the bearing oil feed and drain lines, and cover the ends with plastic.
b. Install a bypass jumper on the bearing (feed to drain) with the valve in line.
The bypass jumpers allow the oil to bypass the bearings and mechanical devices during the oil
flush. The valves in the bypass lines allow the oil flows to be maximized in each section during
the flush.
All ac oil pumps are operated during the flush to increase the oil velocities. The bypass jumper
line valves are used to keep from overloading the oil pump motors.
During the oil flush preparation period, all blanks that have been installed are recorded for future
reference. All strainers, orifices, and piping that have been removed are to be kept in a central
location to be installed at the completion of the flush.
6.2 Resources That Should Be Available While Flushing
During a turbine lube oil flush, resources are needed to ensure that the flush is completed in the
shortest time possible while performing the flush in a safe manner. Lube oil is highly flammable,
and the turbine should be kept as clean as possible during the flush. The system should be
constantly monitored during the oil flush to verify that oil does not leak at any of the penetrations
at the reservoir, pedestals, end bells, valve servos, or any of the temporary connections. Lube oil
flushes are performed around the clock until the flush is completed. Continuous flushing requires
resources to be available at all hours.
During the flush, mechanics are required to:
Monitor the oil system
Check motor loads
Make valve changes
Clean screens
Change filter elements
Stop oil leaks if found
The number of mechanics that are needed will depend on the size of the unit being flushed.
Generally, two mechanics per shift are sufficient for a small turbine, and four mechanics per shift
are sufficient for a large turbine.

Oil Flushing
6-4
A chemist is required during the oil flush to perform oil sampling and oil cleanliness tests. The
chemist can be one of the station chemists, or an outside lab can perform the testing. The oil
samples must be taken at regular intervals to determine the progress of the flush. One chemist
must be available on each shift. The chemists should coordinate the testing so there is no need
for their continuous involvement in the flush.
Station operators are needed to
Start and stop the lube oil pumps
Coordinate the heating and cooling of the oil
Give advice on the operation of the system
The operator might also choose to monitor the oil pump motor loads. One operator must be
available on each shift. The control room operator might choose to have an auxiliary operator
also available to perform some of the flushing duties.
A field engineer (manufacturers representative) is required on each shift to direct the mechanics,
chemists, and operators. The field engineer (technical director) determines the period for each
segment of the flush, monitors the oil cleanliness, and coordinates the craft. The field engineer is
usually the person responsible for the coordination of the entire oil flush. The field engineer is
familiar with the turbine lube oil, control oil, and generator hydrogen oil systems. The field
engineer knows the proper methods for setting up the flush, performing the flush, and returning
the oil system to its proper operating condition after flushing is complete.
If a union hall supplies the craft performing the flush, a supervisor to work with the craft will be
required on each shift. Depending on the station, the supervisor may be able to perform the
duties of one of the other craft involved with the flush.
6.3 Precautions While Flushing
During the oil flush, special precautions must be taken to ensure the safety of the personnel and
the cleanliness of the oil system. Serious damage can occur if the lube oil catches on fire. Many
plants have had serious oil fires that have resulted in total destruction of the turbine-generator
set. The following precautions are to help the maintenance personnel keep the site safe while
cleaning the turbine oil systems:
Avoid any burning, welding, smoking, or open flame in the turbine areas during the flush.
Hot oil vapors will ignite when exposed to open flame. Post signs around the turbine to this
effect to alert others who might not be involved with the flush.
Do not exceed the nameplate rating on totally enclosed fan-cooled or explosion-proof
motors. Open drip-proof motors may be operated continuously at 15% above rated amps for
flushing.
Verify that all temporary hoses are secured before starting the pumps.

Oil Flushing
6-5
Do not remove the plastic pedestal covers during the flush unless necessary. These covers
keep oil vapors in and dust and dirt out.
Make certain that extra fire extinguishers are readily available around the turbine, valves,
generator, and oil reservoir.
Establish the proper emergency communications with the control room in the event that an
emergency shutdown of the pumps is required.
When flushing the generator seal oil system, make sure that no oil backs up into the
defoaming tanks.
Do not allow water to leak into the oil system during the flush. Water can cause oxidation in
piping and pedestals and will contaminate the oil system.
Be careful while working around hot oil and hot water. During the flush, the oil must be
heated to loosen contaminants from the system.
Limit the hot water to 190F (87.7C) for units with cast-iron water box heads and to 200F
(93.3C) for units with steel water box heads.
Ensure that all connections, flanges, etc., are thoroughly sealed to keep oil from leaking from
the system during the flush.
Check for oil spills each time the oil pumps are started.
Have operators and crew communicate by using two-way radios during the flush. This will
allow the pumps to be shut off quickly in case of an oil spill or an emergency.
Monitor oil filter differential pressure to keep the filter cartridges from collapsing. High
differential pressures can develop quickly during an oil flush.
Monitor the return screens in the oil reservoir to keep oil from overflowing during the flush.
Monitor oil levels in the pedestals to keep oil from overflowing at oil seals. Throttle the oil
flow valves as needed in bearing bypass jumpers to keep the oil from overflowing at the
pedestals.
Monitor the oil contamination level at regular intervals to complete the flush in the shortest
time possible.
Flush the components in the correct sequence. Do not allow dirty oil to enter areas that have
been previously flushed.
Always use lint-free rags when cleaning components. Lint from the rags can contaminate
previously cleaned areas.
6.4 Oil Cleanliness Criteria
The cleanliness of lube oil systems can be measured using different methods. The approved
method for Siemens-Westinghouse turbines is to circulate oil through a filter for 30 minutes. The
filter is then taken to a chemistry lab and analyzed for contaminant levels. The approved method
for General Electric turbines is to collect a 100-ml sample (grab sample) in a bottle from various
locations. The samples are taken to a chemistry lab and analyzed for contamination levels.

Oil Flushing
6-6
The method for collecting samples using the filter method is as follows:
1. Protect the sample location from surrounding contaminants.
2. Isolate the strainer by closing the ball valve.
3. Rinse the strainer housing with solvent.
4. Open the strainer petcock, and drain the strainer housing.
5. Open the strainer housing.
6. Rinse down the strainer housing, and cap the interior with solvent.
7. Insert a clean sample screen (150 mesh).
8. Close the container.
9. Close the drain petcock.
10. Open the isolation ball valve.
11. Run the oil sample flow through the strainer for 30 minutes.
12. Close the isolation ball valve.
13. Open the drain petcock.
14. Rinse down the strainer housing with solvent before opening.
15. Open the housing, and remove the sampling strainer.
16. Place the sampling strainer into a clean container.
17. Close the strainer drain petcock.
18. Close the strainer housing.
19. Open the isolation valve to allow continuous flow.
20. Transport the containers to the designated location for sample counting and analysis.
The method for collecting samples using the grab sampling method is:
1. Remove the cap and plastic film from a sample bottle.
2. Dip the container into the oil volume, or hold it under a flowing stream of oil.
3. The sample locations are at the pump level in the oil tank, in the detraining section of the oil
tank, at the oil purification discharge in the main oil tank, and at the bearing header at the
front standard.

Oil Flushing
6-7
4. Replace the film and cap on the bottle.
5. Wipe the outside of the container, and transport the containers to the lab for analysis.
Determining whether the oil meets the cleanliness criteria after using the filter sample method is:
1. Wash the sampling strainer with a clean fluid, collecting all residue on a 200-mesh filter into
a vacuum flask.
2. Remove the filter membrane and, using a 10X-scaled magnifier, scan the filter to determine
the particle size and the number of particles in the 0.005.010" (0.1270.254 mm) range.
3. Do not attempt to move or rotate the particles while scanning.
4. Acceptable criteria are: no hard particles above 0.010" (0.254 mm) are allowed and less than
five hard particles in the 0.0050.010" (0.1270.254 mm) range.
5. Soft particles may exceed the above criteria and are not considered harmful.
6. Soft particles can be readily crushed between the fingers and include lint, paper, sawdust,
asbestos or other insulation, and tobacco.
7. Label and date all samples removed from the system to be compared with samples taken at a
later date.
The cleanliness criteria for the grab sampling method are summarized in Table 6-1.
Table 6-1
Recommended Cleanliness Criteria
Preferred Maximum Allowed (Acceptable)
0.0050.010 mm less than 32,000 0.0050.010 mm less than 128,000
0.0100.025 mm less then 10.700 0.0100.025 mm less then 42,000
0.0250.050 mm less than 1,510 0.0250.050 mm less than 6,500
0.0500.100 mm less than 225 0.0500.100 mm less than 1,000
0.1000.250 mm less than 21 0.1000.250 mm less than 92
Greater than 0.250 mm None Greater than 0.250 mm None
Shown are number of particles per 100 ml sample of oil
The procedure for counting the number of particles in the oil sample is outlined in the Society of
Automotive Engineers, ARP-598A [51]. This procedure says to filter a given volume of oil
through a membrane and to count and size the particles deposited on the membrane by using a
microscope. Many independent testing labs perform oil analyses, and most large oil companies
perform oil particle counts. The acceptable range for the maximum number of particles is similar
to the SAE Class 6, and the preferred range for the maximum number of particles is similar to
SAE Class 4 contamination levels.

Oil Flushing
6-8
A comparison of the cleanliness levels of turbine oil is provided by the International
Organization for Standardization (ISO). The Solid Contamination Code used by ISO is assigned
based on the number of particles greater than 5 microns per unit volume and greater than 15
microns per unit volume. ISO Code 16/13 is approximately equivalent to in service oil
cleanliness recommendations provided by turbine manufacturers.
6.5 Heating and Cooling the Oil Without Damaging the Bearing
The lube oil should be heated during the flushing operation to increase the flow of the oil and to
thermally shock the lube oil piping. The higher oil flow will allow turbulent flow to occur, which
will help to dislodge debris that is lodged in the lube oil piping. The heating and cooling of the
lube oil piping thermally shocks debris from the piping and allows it to be carried downstream
into screens and filters where the debris can be removed.
The heating of the oil must be done carefully to keep from damaging the oil or the oil system.
During the flush, the turbine lube oil is usually heated in one of the lube oil coolers located at the
oil reservoir. The oil coolers use cold water to cool the lube oil during operation of the turbine.
One of the coolers should have cold water flowing through it and the other should have hot water
flowing through it. This will allow the use of the cooler transfer valve to transfer from hot oil to
cool oil during the flush.
The methods used for heating the lube oil are:
1. Use hot water from an auxiliary supply.
2. Mix steam and water in a closed system, and then pipe the hot water to the cooler.
3. Mix steam and water in an open system, and pipe the hot water to the cooler.
4. Immerse cal rods in the lube oil reservoir.
5. Immerse a coil in the oil reservoir, and pass hot water through it.
Some power stations have the ability to make hot water to use for heating. This hot water can be
piped into the lube oil cooler heads to heat the lube oil. Care should be taken to ensure that the
oil is heated in the prescribed manner to keep from damaging the oil.
Steam and water can be mixed in closed or open systems to supply hot water to the oil cooler. If
steam is used to heat water, care must be taken not to overpressure the system or to alloy steam
into the oil cooler.
Cal rods can be used to heat the oil directly by immersing them in the oil reservoir. These heaters
must be the correct types to heat the oil properly. The main problem with the cal rods is that a
suitable power supply is not always available.

Oil Flushing
6-9
The last method for heating the lube oil is to immerse a coil into the reservoir and pass hot water
or steam through the coil. The size of a coil that is large enough to heat the oil is usually too big
to fit into the oil reservoir through the openings at the top of the reservoir.
The oil temperature should be brought up to 180F (82.2C) when heated. When using water to
heat the oil, the water to oil temperature differential should be limited to 100F (37.7C)
maximum. For coolers with steel water box heads, the water temperature should not exceed
200F (93.3C). For coolers with cast-iron water box heads, the water temperature should not
exceed 190F (87.7C).
The preferred method of heating oil is to pipe hot water to the oil cooler and use the cooler to
heat the oil. The oil may be heated in one cooler while the system is being flushed using the
other heater.
6.6 Minimizing the Use of External Piping While Flushing
Lube oil system cleanliness is essential after a turbine-generator outage and before the turbine is
put on turning gear. The ideal lube oil supply has full flow filters installed that filter the lube oil
going directly to the bearings. The only unprotected piping that must be cleaned is located
between the filter and the bearing. A modified flush can be completed using the turning gear oil
pump (TGOP), orifice strainer toggle blanks, valve, connecting pipe, hose, and 100 mesh filter
bags. A modified TGOP flush can be completed as bearing standard assemblies are being
completed and readied for closure. Orifice strainer toggle blanks are installed in all bearing
locations. The orifice strainer toggle blank will prevent oil flow to a bearing and standard when
the bearing is unassembled but will allow flushing in another area.
The oil piping to the completed standard is flushed using the TGOP with either the orifice
strainer in place or the toggle blank installed and unseated. The assembly shown in Figure 6-1 is
also installed to allow oil flow through the piping and bearing lower half. A 100-mesh bag,
acting as a tell-tale, is added to the end of the drain hose. The 100-mesh bag is the indicator for a
clean line.

Oil Flushing
6-10

Figure 6-1
Oil Flushing Piping
The example provided references a system with full-flow filtration before the bearings. The
bearings have temporary piping coming out at the horizontal joint to which is attached a 100-
mesh filter. A modified oil flush can be done without having this full-flow filtration before the
oil inlet to the bearings.
6.7 Flushing Without an External Filter
During maintenance inspections, turbine lube oil flushes are often performed without the use of
external filters. Flushing the turbine without external filters requires more time to clean the oil
system, but it can be less expensive than with external filters. If external filter canisters are not
used, some way to remove contaminants must be provided.
In the past, fine mesh screen (100 mesh) has been used to catch the contaminants from the lube
oil as the oil passes through the bearing strainers. This method of cleaning the oil is not effective
because it reduces the volume of oil flowing through the piping. A more effective way to remove
the contaminants from the oil is to install a bypass jumper around the bearing to increase the
volume flow rate and to install a fine mesh filtration bag on the jumper where it exits the pipe in
the bearing cavity. This method allows the flushing of a few bearings at a time, which allows the
flows to be turbulent in the piping section that is being flushed. The filtration bag will have
sufficient surface area to allow high volumes to flow while removing the contaminants from the
oil. These filter bags can be made of nylon or cloth.
The detraining section of the oil reservoir is also an area where contaminants can be recovered
during an oil flush. The oil in the detraining section must pass through bayonet screens on its
way back to the oil pumps. Fine (100 mesh) mesh should be placed on these bayonet screens
during the oil flush to capture the large contaminants in the oil. The screens should be checked
periodically to ensure that the oil does not flow over the screens as they become clogged with

Oil Flushing
6-11
particulate matter. It is recommended that the oil reservoir have two bayonet screens at the
detraining section. This allows the oil to always have one fine screen to pass through while the
other screen is being cleaned.
One of the most important steps in the oil flush is to drain the oil from the reservoir and
thoroughly clean the reservoir before beginning the flush. The oil reservoir has many areas
where contaminants settle. During the flush, oil flows are increased, and these contaminants
become suspended in the oil. As these contaminants travel throughout the oil system, they allow
clean areas to become contaminated. Oil coolers often trap contaminants and should be cleaned
before flushing. After the oil reservoir is cleaned, it should be filled with clean, filtered oil. The
turbine oil that comes from the vendor frequently does not meet the cleanliness criteria and must
be filtered prior to filling the reservoir.
It is important that the oil purification system be placed in service during the flush to clean the
oil in the reservoir. Some owners have permanently removed the bowser from the unit and have
installed a kidney loop oil filtration system, which provides superior filtration of the oil. These
kidney loop systems also remove more water from the oil than the bowser.
The oil reservoir has doors with rubber gaskets that seal the doors to keep contaminants and
water out of the oil. These gaskets should be cleaned and checked to ensure that they are working
properly. The vapor extractor should be in operation during the oil flush to allow the oil system
to work properly. Some turbines require the vapor extractor to be in operation when the oil
pumps are on to keep from overflowing the bearing pedestals. Vapor extractors are used to keep
moist air from contaminating the lube oil.
6.8 Techniques to Get Maximum Flow Through Piping
In Section 6.1, there was much discussion about the preparations that must be performed for a
lube oil flush. An emphasis on the preparation for the oil flush discussed bypassing the
components to enable getting a higher oil velocity in the pipe being flushed. The components
that were bypassed had bypass jumpers installed from the feed lines to the drain lines (oil sump
in the pedestal). The reason to bypass the components was to keep contaminants out of the clean
component and to increase the flow at that location. The components that had bypass jumpers
installed were:
Bearings
Thrust bearing wear detector
Turning gear
Valve servos
Front pedestal mechanical components
Generator hydrogen seals

Oil Flushing
6-12
The bypass jumpers allow the oil to bypass the bearings and mechanical devices during the oil
flush. The sequential valving of the bypass lines allows the oil flows to be maximized in each
section during the flush. During the flush, the ac oil pumps on the reservoir are operated to
increase the oil velocities. The bypass jumper line valves are also used to keep from overloading
the oil pump motors.
Another way to increase the flow of oil in the lube oil system is to install a supplemental high
velocity flushing pump on the system. The supplemental oil pump is sized according to the main
bearing feed header diameter. These pumps can deliver 2,0005,000 gallons (7.5718.93 kl) of
oil per minute to allow the oil flow to become turbulent in the piping. The supplementary oil
flushing pumps are necessary when the auxiliary oil pump motor is not large enough to flush the
main bearing feed header. If the auxiliary oil pump does not have enough power to deliver the
required flow at the proper pressure, the supplemental oil pump will produce a moderate
reduction of the time required to perform the oil flush.
The engineer must determine when it is economical to use a supplemental oil flushing pump. If a
supplemental pump is required, the desirable type of pump is an electric-driven centrifugal
pump. These pumps get their suction from the bottom of the oil reservoir and discharge into the
top of the reservoir. There is a gate valve on the pump suction and discharge line and a bypass
line around the pump to control the flow rate.
On General Electric turbines, when the oil-driven booster pump is removed, the pump discharge
can be connected to the plate where the booster pump is mounted. Two bypass lines with throttle
valves are also connected to the booster pump plate. When using a supplemental pump, all
connection piping must be cleaned before being connected to the reservoir. Flexible stainless
steel connection piping is often used to connect supplemental pumps.
The oil cooler maximum pressure must not be exceeded when using a supplemental oil pump.
This pressure can be found on the cooler nameplate. One of the oil coolers will need to have the
internals removed and blanks installed to allow for high oil flow through the cooler. Care must
be taken to ensure that there are no leaks at the pump, reservoir, cooler, or piping when using a
supplemental pump.
Filtration skids are often employed when using supplemental pumps to allow for faster cleaning
of the oil. These skids have two canisters that have differential pressure gauges installed to
monitor the pressure differential across the filter. Many spare filter cartridges are needed when
using filter skids.

7-1
7
ROTOR ALIGNMENT AND BALANCING
During reassembly of the turbine-generator, significant delays can be avoided by the way in
which the engineer treats the massive amount of information needed to align bearings and
couplings and to rebalance the rotor. Lack of semi-automated or automated means to collect,
process, and relate clearance or alignment measurements to the original design specifications can
cause problems to be missed until the process of turbine assembly begins. Inefficient
management and processing of tight wire information can further contribute to lost time finding
internal alignment and balancing solutions.
This section of the guidelines presents a generic discussion of the advantages and limitations of
different alignment techniques and practices currently applied within the industry. Included in
this discussion is a review of techniques for automating the alignment process and the
requirements for their application. The discussion proceeds to issues and techniques for
automating the alignment process and the requirements for their application. The discussion
continues with issues and techniques for balancing the rotor and criteria that can be used to
decide allowable vibration limits.
An alignment and a balancing primer are available in Volume 3 of this series. The alignment
primer covers both coupling and tight wire alignment problems in detail. The balancing primer
includes a discussion of issues associated with turbine-generator vibration diagnostics related to
balancing. Also included in this series is guidance in the TGAlign (English and SI units versions)
software developed by EPRI that optimizes the coupling alignment with a minimum number of
bearing moves or no bearing moves.
The EPRI report Shaft Alignment Guide, TR-112449, [52] has been developed to provide
information on the fundamental causes and effects of misalignment on machinery and the
fundamentals of shaft alignment.
7.1 Different Tight Wire Techniques
When performing internal alignment on turbine-generators there are four methods used to record
alignment data:
Tight wire
Arbors
Precision optical scopes
Helium Neon (He Ne) lasers

Rotor Alignment and Balancing
7-2
The tight wire method has been used for many years and is a method that is often used for
turbine alignment. Many millwrights are familiar with this process, and many power stations
have the special brackets and tools needed to perform tight wire alignment.
When the tight wire method is used, a wire is set to special set points at the ends of the turbine
casings. The wire is fixed at one end and has a weight suspended from the other end. Sag charts
have been developed for specific wire diameters and wire weights. Most turbine maintenance
engineers are trained in the tight wire alignment method and can supervise the data collection
with ease.
The limitations to using a tight wire for turbine component alignment are:
It is easy to accidentally move the set points.
The wire sag must be compensated for.
The wire must be moved when installing lower components.
It is difficult to get tops-on readings.
The readings obtained with a tight wire are accurate within 0.001" (0.0254 mm), which is within
the tolerance for alignment. When the wire is bumped, the set points must be checked to ensure
that the wire has not moved. It is very easy to accidentally hit the wire and move the set point.
During the tight wire alignment process, much time is spent setting the wire to the set points. The
wire sag must be compensated for and can cause errors in the alignment process.
Any time a lower component is installed, the wire must be removed and set up again after
installing the component. If there are many component moves, the wire setup time can be a
considerable amount of the alignment time. When it is necessary to take tops-on readings, it is
difficult to get inside the casings to take the wire readings without moving the wire set points.
There is also a limit to the number of internal components that can be installed during the tops-
on readings when using a wire. The person taking the data must have enough room to take the
wire readings, which is difficult with small diameter components.
Another method of internal alignment data collecting is arbor alignment. This method requires an
arbor be built specifically for the turbine casing that is being aligned. The arbor can have dial
indicators mounted to it, or it can have proximity probes mounted to it to collect the alignment
data. The preferred method for collecting data when using an arbor is to use proximity probes.
The arbor with proximity probes allows for easy data collection when performing tops-on
alignment.
Limitations to using an arbor are:
The arbor sag must be compensated for.
The arbor must be moved when installing lower components.
The arbor is heavy if not made from tubing or pipe.

7-3
Fabrication of an arbor requires a significant amount of time and may impact the outage
critical path time if done during an outage.
Arbors are expensive.
An arbor may require modification for each turbine casing.
Data collection goes very quickly when using an arbor and proximity probes. Arbors can be
saved for future use and, in some cases, can be modified to be used on more than one turbine
casing.
Precision optical scopes have been used for internal alignment with limited success. These
scopes require special targets be made to collect the alignment data. There are limited resources
available when using optical scopes, and this method is not very popular for large steam turbines.
There is no need to compensate for sag when using an optical scope.
The limitations for using an optical scope are:
Limited resources are available.
They need a highly trained operator.
Special targets are required.
They are expensive.
They are affected by heat.
They are delicate and can be damaged easily.
Helium neon lasers are constantly being developed and improved for use in internal turbine
alignment. Lasers are becoming the preferred method for internal alignment because they are
very accurate and can shorten the time for performing the alignment. Lasers can be used to take
flatness and perpendicularity measurements that are not possible with other methods. The laser
can take joint flatness readings, casing fit readings, and radial position readings. Lasers can be
set up for short or long distances for internal alignment purposes. The readings are easy to take
once the laser is set up. There is no need to compensate for sag when using a laser. There is no
need to move the laser when installing lower components, so alignment moves can be performed
much faster.
The limitations for using a laser are:
Limited resources are available.
They need a highly trained operator.
Special targets are required.
The laser light can be deflected by heat and smoke.

7-4
7.2 Information Collected from the Unit
A comprehensive slow-speed balancing package should contain a complete vibration history and
a record of the vibration readings before and after each in-service balance shot. Also, the type of
shotstatic or coupleshould be recorded. In-service balance shot data provides specific
information for each rotor balanced. The sensitivity and high spot numbers can be developed for
each rotor. Rotor critical speeds should also be logged during startups. Rotor run-outs should be
maintained, especially for rotors that have increasing bows. The run-outs can be plotted to
provide a time-effect change of the run-out and assist in planning for refurbishment or
replacement. Figure 7-1 shows a 10-year tracking of rotor bowing.

Figure 7-1
Ten-Year Record of Rotor Bowing
Rotor work done during the outage should be included in the balancing reference plan. The
following is a typical slow-speed balancing process:
1. Determine the rotor weight, location of balancing planes, unbalance tolerances, etc., before
slow-speed balancing.
2. For each balance plane, record the balance weight mass, angular location, and balance plane
location for all (both factory and field) previously installed balance weights. Leave the
factory weights in place, but remove and resolve the field balance weights.
3. Prepare the couplings for slow speed balance by measuring the coupling bolt hole fit
diameters and, if the hole fits are not within 0.003" (.0762 mm) of the smallest diameter fit
area, install appropriately sized shim stock the length of the fit area in the oversize bolt
hole(s). For example, if the fit diameter of a single bolt hole was 10 mils (0.254 mm) larger
than the remaining holes in the coupling, a piece of 5-mil (0.127-mm) stainless shim stock
would be rolled to the fit diameter and cut to the length of the hole fit and installed in the
hole.

7-5
4. Remove any coupling spacers before balancing except those that are bolted and doweled.
5. Rotate the rotor at a slow speed (typically around 200300 rpm) to remove any temporary
static bow.
6. Record the total indicator run-out (TIR) of the rotor at several planes including the mid-span
of the rotor. Typically, run-out is recorded between each turbine stage, at the oil seal areas,
the journals, and the couplings. It is not unusual to see rotor bow of less than 0.003" (0.0762
mm).
7. Use the factory grooves to balance the rotor during the slow-speed balancing process.
Typically, the mid-span balance location is not used for LP rotor during slow-speed
balancing.
8. After balancing to the specified criteria, compare the required weights and locations with the
removed weights.
9. Install the appropriate weights. Use the mid-span location for HP and IP rotors, especially if
they are bowed. (A bowed rotor is one with greater than 0.003" (0.0762 mm) TIR.) The
slow-speed balance weight distribution for a bowed rotor is determined by the location (end
planes or mid-span) of the bow in the rotor.
7.3 Automated and Semi-Automated Alignment Processes
The steam turbine alignment process consists of internal alignment (stationary components) and
shaft alignment (couplings). The internal alignment consists of the alignment performed on
casings, stationary blades and diaphragms, oil pump, and governor stand. Shaft alignment
consists of the alignment of each turbine shaft (rotor or spindle) to its adjacent shaft.
Computer programs can assist in the internal alignment process. These programs can determine
the optimum placement of each component and can perform these calculations very quickly after
the data have been entered into the program. The turbine manufacturers use computer programs
to perform internal alignment on their equipment. This alignment software is available for
purchase by turbine owners if they choose to perform the alignment themselves. The collection
of alignment data has also been automated, and there are electronic devices that record and store
data using computers. These data can be downloaded into automated alignment programs to
speed up the alignment process.
In addition, computer programs such as TGAlign can assist with the shaft alignment process and
save considerable outage time when used on large multi-rotor machines as previously described.
The program calculates the optimum bearing moves to achieve an expected alignment within
user-specified alignment and move limits. Output reports specify radial positions at oil or gland
bores along with shim changes for each bearing that is moved. Changes can be calculated very
quickly for different alignment requirements. Previous methods for calculating bearing moves
were performed by hand and could take hours. After the data are entered into TGAlign, the
program can calculate alignment moves in seconds with no math errors. Lasers can be used to

7-6
assist with the collection of coupling alignment data. Before the use of lasers, these data were
taken with micrometers, sliding parallels, and a dial indicator.
During the shaft alignment process, the shafts must be turned to collect data. This process is
complicated due to the weight of the turbine shafts and the need for the shafts to be stopped at a
precise location with no binding in the coupling. A device called the Hutter Pin has been
developed that assists with this process, and an ac inverter can be used to power the turbine
turning gear. (See Volume 3, Section 3.2 for more details on the Hutter Pin). The Hutter Pin
allows for concurrent rotation of both shafts without binding in the coupling. The ac inverter
allows the turning gear to be operated as a variable speed motor. By operating the turning gear
motor using the ac inverter, the shaft speed can be slowed to obtain better control, which aids in
the data collection process.
A shaft alignment method called strain gauge alignment allows the coupling alignment to be
determined without separating the coupling halves. This method also is the only way to check
shaft alignment while the unit is still hot. Strain gauge alignment is performed by measuring the
strain in the turbine shaft near the coupling. The strain on the periphery of the shaft is directly
related to the concentricity of the two turbine rotors. Strain gauge alignment requires modeling
of the turbine rotors, the installation of strain gages on the shaft on each side of the coupling,
electronic strain gauge data collecting, and software that analyses the data. This method for shaft
alignment is very accurate and results in very low shaft vibration amplitudes.
The limitations of the strain gauge alignment method are:
Modeling of the rotors takes considerable time and effort.
Strain gauges must be designed and fit to each rotor.
The cost of modeling each turbine is expensive.
Modifications must be made at the pedestals to enable the recording of data. These modifications
are required to provide access to the strain gauges when the unit is on turning gear. The cost of
the installation is often offset by the benefits of getting more accurate coupling alignment and
getting alignment data without separating the turbine couplings. This method allows the owner to
check turbine shaft alignment if the unit is off-line for only 812 hours.
7.4 Slow-Speed Versus High-Speed Balancing
Slow-speed balancing should be performed on turbine rotors when significant work has been
performed to the rotor. A slow-speed balancing procedure is found in Volume 3 that can assist a
plant to direct or monitor this process. Significant work would include replacement of
buckets/blades, bucket cover replacements, and tie wire replacements. Major work to the steam
path does not include any local hand dressing of the buckets or covers. Balancing would also be
required if any non-cylindrical machining were done to the rotor.
The objective of slow-speed balancing is to get the rotor through the first rotor critical speed
during startup after a major outage. Slow-speed balancing is easily completed at the utility

7-7
facility using portable equipment, but high-speed balancing is not often practical for turbine
rotors. The time to ship the rotor to a high-speed balance location is often greater than the time
required to high-speed balance the rotor during turbine startup. The probability of at-speed on-
site balancing still exists even if the rotor was originally high-speed balanced off-site. The effect
of the off-site high-speed balance may easily be offset by factors that did not exist where the
rotor is balanced, such as assembly, bearing stiffness, loading, dampening factors, and cross
effect. High-speed balance is practical for small, single-rotor turbines where field balancing is
difficult and for rotors that cannot be field balanced to acceptable levels.
The positive impact of a turbine rotor slow-speed balance is not realized in generator fields.
Unlike turbine rotors, generator fields do not have a mid-span balance location. Slow-speed
balance corrects for the first critical mode (graphically exaggerated in Figure 7-2) by placing
weight in the appropriate opposite location to offset the bow or loop. The most effective spot
for the weights is at the location of the bow, which is typically the mid-span location or in close
proximity to it. The grooves for weight insertion into a generator field are located out toward the
ends, outboard of the retaining rings and inboard of the bearings, generally in the fan ring or
similar location. This location for balancing a rotor is commonly called the end plane.
It can be seen that the mode shape of the second critical speed (in Figure 7-2) could be excited
by the incorrect placement of weights that are attempting to compensate for the first critical
mode. The weight placement to compensate for the first critical speed would place one weight
opposite the second critical unbalance and opposite the first critical unbalance and may seem to
be visually effective. But the second weight on the opposite end could end up being placed on
top of the second critical unbalance location, exciting the rotor to greater unbalance and
increased vibration. Most 3600-rpm generator fields operate above their second critical speed
and below their third critical speed. They experience going through the third critical speed during
overspeed conditions.
Most 1800-rpm machines operate between the first and second critical speeds will run above
second critical speed during an overspeed condition. The third critical speed may also be excited
by weights placed in an end plane that attempt to correct for the first critical unbalance.
Therefore, slow-speed balancing is not normally done to generator fields because of the reduced
possibility of positive impact and the possibility of exciting the higher vibration modes.

7-8

Figure 7-2
Exaggerated Rotor Motion for the First Three Field Critical Speeds
7.4.1 Slow-Speed Balance Requirements/Considerations
The manufacturer of the portable balance machine should provide certification of the machines
balance capability for rotor speed and maximum weight. The machine should be sized to carry
the largest rotor in both diameter and length. The vendor that supplies the portable machine
should provide machine footprint and setup requirements as shown in Figure 7-3.
The balancing machine must be lightweight and easy to install without special foundation
requirements. Setup should be quick and easy without the need for extended calibration. The
machine should be capable of sensitive low-speed balancing, which enhances safety and reduces
power requirements. Rotor pedestals must be easy to move for various rotor configurations. The
rollers should be self-aligning, which reduces setup time.

7-9

Figure 7-3
Low-Speed Portable Balance Machine
7.5 When Spin Balancing Is Required
Spin balancing of turbine and generator rotors is performed when the turbine is disassembled and
the rotors have been removed from the machine. Spin balancing is necessary if any of the
following are true:
The turbine rotor has had bucket or blade work.
A rotor is discovered to be bowed.
The generator field has been rewound or has had the retaining rings removed.
The rotor balance has changed without any definite cause.
It is important to note that generator fields may require a compromise balance between the
mechanical and electrical effects on the windings. All fields by nature have some degree of
thermal sensitivity, but a field may bow excessively as loading increases (increase in field
current); if the unbalance exceeds acceptable vibration limits, the field is identified as being
thermally sensitive. The cause of the thermally induced bowing may be uneven temperature
distribution within the field or axial forces associated with differential thermal growth between
the copper windings and steel body not being evenly distributed.

7-10
Thermal sensitivity may be reversible or irreversible in operation. Reversible thermal sensitivity
follows field current (load) both decreasing and increasing. A compromised balance may be
required to offset the thermal vector and maintain the vibration within acceptable limits.
Corrections for reversible thermal sensitivity may be done either off-site or in the stator if the
causes and required balance information are known.
Thermally sensitive rotors may be the result of a field rewind. If strict care is not taken during
the field rewind, the windings may not be uniformly wound, insulation thickness, binding,
uneven friction forces in the slots or under the retaining rings may all be causes of thermal
sensitivity. Re-wedging to clean and repair wedges with improper reassembly or after a generator
field rewind may also result in a thermally sensitive rotor if wedge tightness is not uniform.
Irreversible thermal sensitivity follows an increasing field current but does not reduce with
decreasing field current, or it may partially reduce and then lock in. This condition typically
will limit loading and unit operation. Often, the unit must be taken off-line to turning gear
operation to unlock the restrained forces. This condition typically cannot be compensated for
with a balance program but requires field disassembly, rewinding, and then balancing.
Most spin balancing is performed at low speeds and can be performed at the power plant using a
portable balance machine. In some cases, the portable lathe that is used to machine the rotor can
also perform the spin balance of the rotor. Low-speed spin balancing is done at speeds below 500
rpm, and the speed varies depending on the size of the rotor and the length of the blades.
High-speed balancing of turbine and generator rotors is performed off-site in special balance
chambers (or pits) or on-site during startup. Balance chambers are designed to spin the rotor at
speeds up to the design overspeed of the rotor. For turbines, these speeds are up to 112% of rated
speed and, for generator fields, up to 120% of rated speed. It is possible for some high-speed
balance chambers to run the balance test at design conditions with heating of the generator field
to determine if the field has any shorted windings.
All high-speed balancing pits have the ability to pull vacuum to be able to spin rotors up to rated
speed without overheating the blades. High-speed off-site balancing may not always be practical
for these limiting factors:
Travel time
Rotor size
Spin pit capacity
Spin pit schedule
Balancing duration
Rotor availability during the outage
The adverse effect of these factors may force high-speed balancing, which can be done only
during the startup period of an outage.

7-11
High-speed balancing may be necessary any time a generator field is rewound. Balancing of the
generator field in the stator is very difficult and can take a considerable amount of time and
effort. Off-site high-speed balancing of turbine rotors is suggested if the unit is a large base-
loaded unit, and the cost of lost generation due to downtime is high. Performing a high-speed
balance is expensive, and it is difficult to transport rotors to the balance chambers. If the cost of
lost generation is greater than the cost of the high-speed balance, a high-speed balance is
recommended. Balance programs in the power plant after a maintenance inspection can take a
considerable amount of time, and they are always on the critical path of the outage. A high-speed
balance specification that can be used for a turbine, generator, or exciter rotor is provided in
Volume 3. The specification includes guidance and acceptability requirements for unbalanced
vibration of rotors balanced in a high-speed spin pit.
Off-site high-speed balancing of small turbines or turbines that have low capacity factors is
generally not recommended. It is usually more cost effective to perform a low-speed balance on
the rotor and trim balance the unit when it is started. There may be special cases that require a
high-speed balance of a small turbine, but normally, the cost prohibits this work.
If many rows of blades are replaced or if the rotor is bowed and requires a lot of machining
work, the investment for a high-speed balance may be justified. A high-speed balance should
follow all generator field rewinds.
7.6 On-Line Balancing Devices
On-line balancing devices are widely used on smaller non-turbine applications, such as reactor
coolant pumps, industrial fans, grinding spindles, machining centers, etc. This technology is
being adapted to turbine-generators. For example, technology is currently available for an active
balancing system for turbine application that corrects for imbalance while in operation. The
obvious advantage of an active on-line balancing system is the time saved during startup and
while on-line to correct unbalance conditions. An active on-line balancing system would also
allow correction above and below rotor critical speeds, optimizing the critical speed transient
vibration. Table 7-1 presents selected specifications of a high-speed turbomachinery active
balancing system.

7-12
Table 7-1
Specifications for an On-Line Active Balancing System
Parameters Range
RPM speed 50015,000
Balancer capacity Up to 200 oz-in. (14.40 kg/cm)
Temperature range -67 to 302F (- 55 to 150C)
Humidity 10% to 90% non-condensing
Balance functions Automatic multi-plane balancing
Operator-initiated auto sequence
Operator-confirmed individual step
On-line system identification
Automatic single-plane balancing
Manual balance weight positioning
7.7 Potential Consequences of Not Balancing the Rotor
The objective for slow-speed balancing an individual rotor during an overhaul is to increase the
probability that the rotor will pass through its critical speeds during startup and achieve running
speed without tripping due to high vibration. The time necessary for high-speed balancing of the
rotor after the overhaul has been completed should be reduced. When work has been done on a
rotor during an overhaul, it is estimated that 50% of them do not make operating speed if no
slow-speed balancing has been performed. It has also been estimated that rotors that have been
slow-speed balanced during an outage have a 95% probability of reaching operating speed
without a balance shot and that more than 80% of rotors do not need high-speed trim balancing
during startup after the outage has been completed.
In the machine, balance shots are normally done at rated speed conditions; therefore, the data to
calculate a shot is at speed. It is much more difficult to calculate a balance shot before getting to
rated speed. The reference information used to calculate a balance shot is:
1. Sensitivity in oz./mil (g/mm) is used to calculate the amount of weight to offset the
imbalance.
2. The high spot number is used for the angular placement of the weights.
The amount of weight required and the calculated angular component is obtained from plotting
and resolving the imbalance vectors on polar graph paper. The imbalance vectors are the
amplitude and angle reference of the rotor vibration readings. This information is not normally
available at all the speed variations from turning gear to at speed and may be very difficult to
obtain if the unit is vibrating severely at an off speed condition. The rotor must be held at that
speed, and the vibration readings must be taken to calculate a balance shot with best guess
sensitivity and high spot number. Slow-speed balancing helps the probability of obtaining rated
speed after an outage.

7-13
7.8 Selecting Vibration Limits
There are many causes for turbine vibrations; many of which are discussed at greater length in
the balance primer contained in Volume 3. Vibration limits are necessary to determine the proper
time for turbine balancing. Vibration limits differ depending on whether the unit is starting up
after a long maintenance inspection, or if the vibration amplitudes are increasing during
operation. The turbine manufacturers give limits for steady-state conditions, critical speeds,
maximum levels, and levels for well-balanced units.
The following vibration limits are for mechanical unbalance and are measured peak to peak:
For steady state conditions at high loads on 3600-rpm turbines, the turbine manufacturers
recommend that the shaft vibration levels remain at 4.0 mils (0.10 mm) or below.
At critical speeds, the vibration levels should remain at 8 mils (0.20 mm) or below.
The maximum vibration level for a turbine shaft is 6 mils (0.15 mm).
A well-balanced unit should have vibration levels of 2 mils (0.05 mm) or less.
The vibration trip limits depend upon speed, reason for vibration, and length of time at the
vibration level. The following trip limits are for 3600-rpm turbines:
The turbine should be tripped if the speed is 800 rpm or less and the vibration level reaches 5
mils (0.13 mm).
For speeds between 8002000 rpm, the turbine should be tripped if the vibration level
reaches 10 mils (0.25 mm) or if the vibration level reaches 7 mils (0.18 mm) for two minutes.
For speeds between 20003600 rpm, the turbine should be tripped if the vibration level
reaches 10 mils (0.25 mm) or if the vibration level reaches 7 mils (0.18 mm) for 15 minutes.
For 1800-rpm turbines, the trip limits are 2 mils (0.05 mm) higher than for 3600-rpm turbines
due to their larger mass.
Steady-state vibration limits for 3600-rpm turbines vary by manufacturer. The vibration levels
used most often for high loads for large steam turbines are as follows:
Satisfactory operation 3 mils (0.08 mm) or less
Alarm 5 mils (0.13 mm)
Trip 10 mils (0.25 mm)
When starting a turbine after a long maintenance inspection, it is normal to perform a balance
program. Continuous recording equipment is installed on the unit that records vibration amplitudes
and phase angles for each bearing and possibly for some of the couplings. Vibration levels are
measured at varying loads, and the cause of any unbalance can be determined using the recorded
data. The change in vibration amplitude and phase angle is used to determine what corrective
actions are necessary. Some problems that cause high vibration levels during start up are:
Rubbing
Misalignment

7-14
Water induction
Steam temperature variation
Faulty steam seal operation
Out-of-round bearing journals
7.9 Balance Limits
Out-of-machine slow-speed balance tolerances are a function of rotor weight, operating speed,
rotor type, and applicable or chosen equipment standard. Rotors are classified as either rigid or
flexible. A rotor is classified as rigid if it operates below any resonant frequency. A rule of
thumb states that rotors that operate below 70% of their critical speed are considered rigid.
Flexible rotors are those that operate above 70% of the first critical speed or, in general, operate
above at least one resonant frequency. Therefore, slow-speed balancing is a rigid rotor mode
activity. Table 7-2 provides a listing of some of the available standards that provide information
regarding the balancing of equipment and the balancing of rotors.

7-15
Table 7-2
Sources for Equipment and Rotor Balancing Standards
International Organization for Standardization (ISO)
Specification Subject Content
ISO 1925:1990 Mechanical vibration -- balancing --
Vocabulary
Contains definitions of most balancing
and balancing equipment terms
ISO 1940-
1:1986
Mechanical vibration -- balancing quality
requirements of rigid rotors
Part 1: determination of permissible
residual unbalance
Classifies rotating work pieces and
recommends balance tolerances
ISO 1940-
2:1997
Mechanical vibration balance quality
Part 2: balance errors

ISO 2953:1999 Mechanical vibration balancing
machines -- description and evaluation
Describes for a prospective balancing
machine user how to specify
requirements to a balancing machine
manufacturer, including proposal
requirements, and identifies how to test a
machine to ensure compliance to the
specification
ISO 2954: 1975 Mechanical vibration of rotating and
reciprocating machinery -- requirements
for instruments for measuring vibration
severity

ISO 10814:1996 Mechanical vibration -- susceptibility and
sensitivity of machines to unbalance

ISO 11342:1998 Mechanical vibration -- methods and
criteria for the mechanical balancing of
flexible rotors

American National Standard Institute
ANSI S2.19-
1989
Mechanical vibration -- balance quality
Part 1, determination of permissible
residual unbalance
U.S. counterpart of ISO 1940/1-1986
American Petroleum Institute
ANSI/API Std
610-1995
Centrifugal pumps for petroleum, heavy
duty chemical and gas industry services
Contains vibration and balance limits
Std 611 General purpose steam turbines for
petroleum, chemical, and gas industry
services
Contains vibration and balance limits
Society of Automotive Engineers
ARP1134 Adapter interface - turbine engine blade
moment weighing scale

Military Standards
Mil Std-167-1 Mechanical vibration of shipboard
equipment
Includes basis of acceptability criteria,
methods, and limits

7-16
Each standard provides a different method to calculate the required balancing tolerance or the
amount of residual unbalance in a rotor. Figure 7-4 is a plot of the impact of various standards on
the amount of remaining unbalance.

Figure 7-4
Various Standards for Residual Unbalance
The following are examples of tolerances applied for slow-speed balancing:
High-pressure rotor 18 ounce-inches/plane (12.96 gram-meters/plane)
Intermediate-pressure/reheat rotor 36 ounce-inches/plane (25.92 gram-meters/plane)
Low-pressure rotor 70 ounce-inches/plane (50.4 gram-meters/plane)
These tolerances are a slight modification from Mil. Std. 167-1 that states:
oz-in = 4 W/N
Where: W= rotor weight in pounds for the plane
Example, for a two-bearing symmetrical rotor,
W = Half of the total weight of the rotor
N = The operation speed of the rotor, for greater than 1,000 rpm
A balancing tolerance is applied because it is not necessarily reasonable to take a balance level
down to loss of phase signal to ensure smooth rotor operation. Modern sensitive state-of-the-art
balance equipment with microprocessor controls is capable of achieving residual unbalance
levels below what is normally required for smooth rotor operation. Therefore, slow-speed
balance tolerance is a combination of choosing the right residual unbalance level and the right
balancing equipment.

7-17
7.10 Access to Turbine-Generator Rotors
Access ports through the HP and IP shells for mid-span and end planes and access to LP rotor
end plane locations through the condenser are provided for field balancing. Mid-span balance
locations may be located through a multi-use location such as rotor pre-warming access. End
plane locations in HP or IP section will usually just penetrate the lowest possible pressure
location of the section. End plane access through shells is usually radial and axially angular. The
balance access and the rotor balance location may not always line up in both cold and hot
positions. Therefore, it is advantageous to observe rotor/shell locations during an outage and
modify the access if required.
Figure 7-5 shows a sketch of an offset modification to a shell bore. The modification is axial and
provides sufficient angularity to catch the rotor balance plane in both the hot and cold positions.

Figure 7-5
Offset Modification to a Shell Bore
The generator field balancing locations are the most difficult to access of all turbine-generator
locations. Access to the HP and IP section is from outside the shells and through the shells. The
difficulty in accessing the HP and IP balance locations may be reduced by removal of the
balance port fasteners or alignment of the balance location on the rotor through the shells.
The LP rotor balancing location is typically accessed through an opening in the LP hood outer
shell. The safety hazards in accessing the LP section may be air quality or elevated humid
temperature, especially if the unit has just been shut down. The hazard in entering a generator

7-18
that has just been shut down to access balance locations is the H
2
and CO
2
that may be present.
The generator casing must be cleared of H
2
and purged of CO
2
prior to entry. But the major
difficulty in accessing the generator balance locations is logistical, as seen in Figure 7-6.

Figure 7-6
Access to Balance Grooves
The balance groove located on the fan ring must be accessed by entering the space between the
outer and inner end shields. At least one segmented fan nozzle ring is then removed to access the
balance groove. The space between the outer and inner end shields is very small.
The person inserting the balance weights must be not claustrophobic, thin, and flexible. These
are legitimate criteria because it is quite possible to get caught on interior fastener lock tabs
while sliding through the limited space. Given the space, it can become extremely difficult to
release caught clothing.
All tools must be tied off to a retrieval string in case they are dropped. Therefore, the generator
shot program is planned very carefully to minimize the number of balance shots required.
7.11 Turbine-Generator Balance Support
When turbine-generator balancing program is performed, all of the necessary tools and
equipment must be on hand before the unit startup. Equipment needed for balancing a turbine-
generator set includes:
Continuous data collection equipment
Power cables, connector cables and rope
Atmosphere tester for both LP and generator balancing
Balance weights for each rotor and coupling
Weight installation tools

7-19
Lights and strobe or phase reference
Balance shot calculation software or a manual means of determining an appropriate balance
shot
Safety harness and appropriate extraction equipment for LP balancing (if access to the LP
balance location is considered a confined space or requires a confined space permit)
The equipment used to collect the vibration data varies for each machine. This equipment can
gather data continuously or by manual means. If the data are collected manually many pieces of
equipment must be checked out before startup. Most systems that are used to gather vibration
data on large steam turbines are automatic. After they are set up, they can collect data
continuously until they are disconnected. These systems use non-contact proximity probes to
transmit the vibration amplitudes and a key phase reference on the shaft to determine the phase
angle of the imbalance.
It is important to make sure the cables are connected to the proper proximity probe and that they
are calibrated to read correctly. This is done during the turbine outage to ensure that they will
work during startup of the turbine. Balance weights for each rotor and coupling should be made
before the balance program and should include all locking hardware.
The balance planes on the rotors should have the weights consolidated during the outage to
ensure that there will be sufficient room available if a balance weight needs to be installed.
Balance weight installation tools should be checked to make sure that it is possible to install a
weight in any location along the shaft if necessary.
When installing balance weights, the engineer should be familiar with each rotor and should
know how to install the weights. Rope will be needed to tie off weights and tools so they do not
be lost if dropped. Lights should also be tied off so they will not be lost if dropped.
The turning gear is used to rotate the rotor when installing balance weights. The engineer should
be familiar with the operation of the turning gear and the allowable time limits for removing a
turbine from turning gear operation when the unit is hot. After the balance weight is installed, the
turbine must be rolled on the turning gear for a sufficient amount of time to allow the rotor
eccentricity to return to an acceptable level prior to starting the turbine. The turbine engineer
should be familiar with these limits before beginning the balancing program.
The calculation of a balance shot is required if the rotor is determined to have mechanical
unbalance. This can be done manually or by balance software. Most manufacturers use computer
programs to plot balance shots. This software is programmed using high spot numbers,
sensitivity to weight, pickup angles, equipment phase angle, and influence coefficients for other
rotors that are coupled along the turbine train. All of these influences are necessary to plot a
balance weight. If the balance weight is plotted manually, the balance engineer should be
familiar with each of the influences and should know how to use them to plot a shot.

7-20
7.12 Turbine-Generator Balance Weights
7.12.1 Split-Weight Design Dovetail Weights
When attempting to install dovetail-style weights during field balancing situations, you may
experience the problem where access to the specific location on a rotor to install a dovetail
weight is not available. Removal of previously installed balance weights to gain access to an
access slot would be necessary. Figure 7-7 shows a typical split-weight dovetail design that can
be used for fast access to the dovetail weight groove at any location, thus not requiring the
removal of previously installed weights. Installing this type of weight can save significant time
and effort in any individual balancing situation. The weight can be replaced with a standard one-
piece weight when the rotor is removed during the next outage where the weights are
consolidated during the slow-speed balance. Typical material for balance weights is 12-chrome
stainless steel (AISI 403).
This split-weight design balance weight uses a long set screw to go through a clearance hole in
the top half of the weight assembly and screw into the threaded bottom half of the weight
assembly. (See Figure 7-7 for details). By installing a nut (to function as a lock nut) on the
exposed portion of the long set screw above the upper half weight, the upper half is fastened
relative to the bottom half, and at the same time, the set screw is tightened in the bottom half
weight against the rotor, locking the two pieces in the balance groove. Securing this style weight
in the balance groove is somewhat of a trial and error process, requiring several iterations of
tightening the outer lock nut and then the overall set screw/nut assembly in place. When
calculating the required weight size, remember to include the set screw and nut as part of the
entire assembly.
As an added precaution when installing the balance weight, the nut may be tack welded to the set
screw and balance weight. Be sure to install Part B first in the balance weight groove before part
A. See Figure 7-7.

7-21

Figure 7-7
Split-Weight Dovetail Weight

7-22
7.12.2 Tungsten-Style Weights
Utilities have used balance weights made of tungsten, a material much heavier than the 12-
chrome stainless steel balance weight material (AISI 403) normally used. However, tungsten is
not as resistant to erosion as 12-chrome stainless material and is more likely to lose mass during
operation due to exposure to the harsh operating environment inside the turbine; therefore, some
precautions should be taken when using this type of weight material.
For the LP sections of a unit where moisture is present, dovetail-style tungsten weights can be
employed to get more weight in a smaller location; however, the weight should be coated with
cadmium to prevent water erosion of the tungsten material. There are companies in the United
States that are capable of performing this coating process, which obviously would require some
lead time prior to needing to install the weights in the unit.
Use of tungsten material for plug-type weights in the HP and IP sections (and any LP sections
that may use plug weights) of the unit is usually accomplished by drilling out (counter-boring)
the standard field balance plug weight from the bottom side of the plug and then inserting the
tungsten material into this counter bore with a size-to-size fit. The plug is then circumferentially
seal welded at the tungsten/12-chrome interface to prevent the tungsten from falling out of the
standard plug either during installation or removal. This process captures the tungsten material in
an erosion-free atmosphere, while also giving the effect of more weight in the same size standard
plug.

8-1
8
PRESTARTUP CHECKS
Currently, the procedure for realigning hydraulic controls is slow, and relies heavily on the
availability of an experienced controls engineer and staff of mechanics to relay valve strokes and
hydraulic pressures. While the resetting of controls is still somewhat of an art, it is beneficial to
establish the practices and procedures used to guide the performance of resetting the turbine
controls and prepare a checklist of activities that should precede the return of the unit into
service.
This section of the guidelines provides a compilation of practices, procedures, and experiences
relating to unit startup after overhaul. A review of advances in neural networking techniques that
have been used to set boiler controls is included as an emerging technology that could possibly
be adopted to automate the procedure by which control line-up problems are solved.
8.1 Steps to Minimize Startup Time
Before the turbine startup, the operator should review the starting procedure and become familiar
with each item so that the operation of the turbine will go smoothly. The units in the power
station seldom are identical, and each turbine will probably have variations in the starting
procedure. It is helpful to create a startup document that identifies and summarizes critical
turbine-generator elements to be observed during each startup process. The document should be
organized to reflect the flow of startup activities and include:
The applicable unit
Topic of concern
Source reference (for additional information or future verification)
Process variables
Limits
Definitions
Actions
The information presented in Table 8-1 shows examples of startup topics and relevant details that
could be included in a startup document. Note that the applicable unit, primary reference, and
other information are not included in this example.

PreStartup Checks
8-2
Table 8-1
Recommended Outline for a Startup Document
Topic Details
Hydrogen Air Leak Test (a) The amount of hydrogen consumed during operation or air during
testing is either absorbed into the seal oil or lost through leakage at the
seals or other locations. (b) The test should be run with the gas
temperature as steady as possible. (c) The generator should be allowed to
thermally stabilize for 12 hours after filling with gas.

Seal Oil Flow (Absorption) Gas Loss (Leakage)

Acceptable Unacceptable Acceptable Unacceptable
515 gpm
(18.956.78
Lpm)
<5 gpm (<18.9 Lpm)
means tight seals that
may be easily damaged.
>15 gpm (>56.78 Lpm)
means seals are open
and when combined with
air side losses, the seal
oil requirements may
exceed the seal oil supply
pump capacity.
<1,000 ft
3

(<28.317 m
3
) per
day
>1000 cfm (>28.317 m
3
per min). Measure seal oil
flow and calculate leak
rate. Typical leak rates
are 400500 ft
3
(11.327
14.158 m
3
) per day
>2,000 ft
3
(>56.634 m
3
)
per day. Locate and seal
loss areas.
Design Gas Loss (Leakage)

300 ft
3
(8.495 m
3
)

per day at 32 psi
(220.6 kPa)
400 ft
3
(11.327 m
3
) per day at 47 psi
(324.05 kPa)
500 ft
3
(14.158 m
3
) per day at 62 psi
(427.5 kPa)
600 ft
3
(16.990 m
3
) per day at 77 psi
(530.9 kPa)
Turning Gear Operation 10:1 ratio of time off to time on up to eight hours of turning gear run time.

H
2
O Induction 50
F (10
C) temperature mismatch is considered H

2
O induction.

T/G Operation After H
2
O
Induction Incident
For temporary rotor bow, 26 hours on gear to remove bow. Humped shell
may need >24 hours.

PreStartup Checks
8-3
Table 8-1 (cont.)
Topic Details
Lube Oil Temperature Unit trip
Turning gear
2 hrs before rolling
Starting
Hold @ 1000 rpm
Exceeding 3000 rpm
Operating
Reduce set point to 7580
F (2427
C)
7580
F (2427
C)
Raise set point to 90
F (32
C)
90
F (32
C)
95
o
F
(35
C) (Off wobbulator at 3000 rpm)

100
F (38
C)
110120
F (4349
C);
<50
F (10
C) [inlet to drain delta T]

Vibration Due to Rubbing

At or below first critical speed: Rubbing occurs at one spot; bowing occurs
in the direction of the rub, which causes the rotor to bow quickly to large
amplitudes.
Trip at 810 mils (0.20-0.25 mm).
Above first critical speed: Rubbing occurs some distance from the high
spot. The effect of the bow is minimized because the rotor tends to
continuously develop a new high spot. Supercritical rubs are thus usually
characterized by unstable vibration amplitudes and constantly changing
phase angles of vibration. Though relatively benign, such rubs should not
be allowed to develop an excessive amplitude (journal vibration 810 mils
(0.20-0.25 mm)) before tripping because deceleration through the first
critical speed will necessarily be somewhat rougher.

Vibration Limits (Roll Up)

< 800 rpm
8002000 rpm
> 2000 rpm
Trip if >5 mils (0.13 mm)
7 mils (0.18 mm) for 2 min, or >10 mils (0.25 mm)
7 mils (0.38 mm), for 15 min or >10 mils (0.25 mm)
12 mils (0.30 mm) max (at critical speeds)

Bearing Metal Temperature

Normal Temperature Ranges:
Tilt pad 180220
F (82104
33
C)
Elliptical 170190
F (7788
C)
Short elliptical 190210
F (7799
c)
Alarm: Tilt pad at 225
F (107
C)
Elliptical at 210
F (99
C)
Maximum temperature: 250
F (121
C)

Vacuum Breaking It is recommended that vacuum not be broken until the unit has reached
2/3 (2400 rpm) of rated speed unless an emergency condition, such as
high vibration, requires the unit to be slowed down as fast as possible.

PreStartup Checks
8-4
Table 8-1 (cont.)
Topic Details
Wobbulator Used to prevent the turbine from running at a constant speed (3000 rpm)
when bucket critical speed might be experienced.

Oil Trip Test <96% of rated speed = <3456 rpm (adjust if it exceeds 3456 rpm).
One-half turn of the spindle will alter speed ~150180 rpm.
Counterclockwise rotation reduces speed; clockwise rotation increases
speed.

Overspeed Testing

The turbine should not be overspeed tested until it has carried 25% or
greater load for at least four hours. The warming period provides time to
raise all rotors above their fracture appearance transition temperature
(FATT). Rotor material is ductile above its FATT (like a rubber band) and is
brittle (like glass) when it is below its FATT. Therefore, by ensuring that
the rotors are above their respective FATT means any indications (cracks,
pits, stress intensification, etc.) will absorb the additional energy created
during the overspeed test.
FATT Generator Note
Bore temperature is to be above FATT.
HP 380
F (193
C)
IP 280345
F (138174
C)
LP 025
F (-17 to 4
C)
LP 70
F (21
C) (refurbished rotors)
One method to retain heat in
the field is by isolating the
closed cooling water (CCW) to
the H
2
coolers.

Amount of time off-line between soaking the rotor and the overspeed test
is dependent on rotor material properties.

Exercise the emergency governor with the oil trip test mechanism when
the turbine rotor is initially coming to operating speed. This ensures the
operation of the emergency governor.

Test Requirements Overspeed protection control (OPC) = 1 test
Trip anticipator = 1 test, if within stated tolerances
Load unbalance protection (LUP) = 1 test
Mechanical overspeed = 2 tests, if within stated tolerances
Backup overspeed test (BOT) = 1 test
Mechanical trip handle at front standard = 1 test

PreStartup Checks
8-5
Before firing the boiler, perform the steps listed here as a way to reduce the turbine startup
duration:
1. Check the oil level in the reservoir to make sure that it is at the proper level.
2. Heat the oil in the reservoir to 90F (32.2C) using the oil pumps.
3. Check the bearing header for proper pressure
4. Check the thrust wear detector for correct alarm and trip point settings
5. Check all valve position switches
6. Check all extraction non-return valves for the correct position.
7. Check the dc oil pumps for automatic operation
8. Reset the turbine to ensure that all valves operate correctly.
9. Start the generator hydrogen seal system.
10. Purge the air from the generator and fill with hydrogen
When the unit is initially rolled on turning gear, the boiler should be fired. The turning gear
should be operated for a minimum of four hours before starting the turbine. During this time, the
HP and IP turbines can be pre-warmed. Each unit will have operating instructions for pre-
warming, and the pre-warming temperatures should be similar for all turbines. The HP turbines
should be pre-warmed to 300F (148.8C) and the IP turbines should be pre-warmed to 130F
(54.4C). The IP will be pre-warmed using the steam seals with the condenser backpressure at 5
in. Hg absolute (12.7 cm Hg absolute).
During the pre-warming stage, the following items should be checked:
Eccentricity of the HP rotor
Casing expansion detector
Differential expansion detector
Rotor expansion detector
HP casing temperature
IP casing temperature
Condenser backpressure
The time required for the turbine start up varies depending on the initial temperature of the
turbine casings. The turbine manufacturers give guideline turbine start rates for starting turbines
for three types of start ups: cold, warm, and hot. The starting procedures are based on cyclic life-
expenditure curves, and these may vary for each type of unit.

PreStartup Checks
8-6
Turbine stress monitors have been developed over the years that can determine the stress in the
casings and can be used for starting and loading the turbine. These stress monitors allow the
turbine to be started at the optimum rate without overstressing the turbine rotor or casings. The
stress monitor can shorten the amount of time to start and load a unit if the starting and loading
curves are conservative. Stress monitors can also be used for condition-based monitoring of the
turbine components. Without the stress monitor, the operator has no way of knowing the actual
stresses; therefore, the starting rate must be conservative.

9-1
9
POST-OUTAGE ACTIVITIES
After the unit is returned to service, there is a tendency to view the maintenance outage as being
completed. In fact, whereas the overhaul activities are essentially completed, there is a unique
opportunity to collect and document information that can be extremely relevant to the planning
and preparation of the next maintenance outage.
This section of the guidelines presents a generic discussion of the information that should be
chronicled as input to the pre-outage planning phase for the next turbine outage. A checklist is
presented of recommended activities that are best performed at the conclusion of an outage.
9.1 Post-Overhaul Engineering Reports
The outage is over, and the unit is back on-line. Now begins the process of accumulating,
evaluating, sorting, logging, and reviewing the information compiled during the outage. The
documentation of the outage work accomplished is an important element of the total work
process. The documentation includes items collected or generated at the following stages of the
outage process:
1. The outage process begins with the identification of the work to be performed:
Operation issues
Previous outage recommendations
Industry-identified concerns
2. The work is planned:
Work packages
Specifications/procedures
Purchase orders
Parts
3. A schedule is developed:
Required activities integrated
Resources available
Timeframe

9-2
4. The outage occurs:
Planned activities
Unplanned activities
5. Activities are performed and documented:
Logs
Records
Measurements
Sketches
Reports
6. The documentation is used after the outage to analyze and evaluate the outage:
Record of what occurred
Data collected
Resources used
Sequence of events
Calendar of events
Duration
Activities
Parts used
Performed as expected
Worked/didnt work
Planning for next outage
The last step of an outage six-element life cycle is the evaluation and analysis of the outage
through the information accumulated during the outage. To what extent the turbine-generator
engineer (or others) evaluates and analyzes the outage determines what post-outage engineering
reports are required. Information is accumulated during the outage to document and
communicate what was found, what was being done, and what things need to be done in the
future. This information may have taken the form of reports, logs, data sheets, updated drawings,
etc. This information may have completed its useful purpose and may be left in its original state
and stored or archived for historical reference. Or the information may be summarized,
condensed, and accumulated with other information into another format or report that is used to
evaluate or analyze the outage.
Table 9-1 lists typical information resources and contents that would be accumulated during an
outage. Matrix arrangement is by typical information sources, and the table identifies expected
contents in that source of information. Contents may be grouped or appear in other sources
depending on outage support, format, etc. Each source of information should clearly identify
unit, outage, component, dates, person, or organization performing the activity.

9-3
Table 9-1
Recommended Information to Be Collected After the Outage Is Complete
Information Source Contents
Brief narrative of job, summary of what was done
Inspection summary (what was found and disposition)
Recommendations
Parts used
Narrative by component grouping of what was found,
what was done, and what was left
Component dimensional readings
As found
As left
Component clearance readings and calculations
As found
As left
Alignment and position readings
As found
As left
Test readings
Technical direction
Startup
Condition assessment
Measurements
Repairs
Recommendations
Diaphragm repairs
Repair duration
Measurements
NDE results
Material properties
Boresonic inspection
Recommendations
Inspection findings, condition assessment
Efficiency calculations
Steam path inspection
Inspection recommendations

9-4
Table 9-1 (cont.)
Recommended Information to Be Collected After the Outage Is Complete
Information Source Contents
Inspection findings
Efficiency calculations
Sealing area inspections
Inspection recommendations
Replacements
Repairs
Measurements
Bucket repairs
Replacement/repair duration
Failure mechanism
Measurements
Bearing repairs
Chemical analysis
Inspection findings NDE
Disposition and cleared inspections
Equipment used
Method(s) used
Voltage
Current type (ac or dc)
Resistance values
Dry bulb temperature
Wet bulb temperature
Relative humidity
Component Temperature
Test readings
Time intervals
Generator Tests
Comments
Orientation Maps
Reference location

9-5
The turbine-generator engineer should at least maintain a summary reference engineering report
of critical information, inspections, results, and recommendations that have occurred during past
outages. As an example, bucket replacements and recommendations should be concisely tracked
and displayed by unit, outage, rotor, and location. The advantages of summary concise
information are:
History at a glance
Trending
Forecasting/planning/outage preparation
Table 9-2 presents examples of several post-outage engineering reports and their contents. Each
report contains the required outage identifiers of unit and year.
Table 9-2
Examples of Post-Outage Engineering Reporting
Engineering Report Contents
Outage dates Outage type, dates and duration
Turbine deck lay-down plan Revisions to plan, especially work centers
Diaphragm repairs Type of repair by diaphragm
- Major
- Minor
Repair hours per diaphragm
Other hours expended
Repair recommendations
Component locations (for
spares)
Component identification
Component serial number
Date installed
Repaired by
Bucket repairs and
replacements
Replacement by stage
Repair by stage
Recommendation by stage
Bearing repairs Repairs by location
Type of repair
Reason for repair
Babbitt chemistry
Repair facility
Rotor runouts Separate plot for each set of data taken
Runout readings plotted by location

9-6
Table 9-2 (cont.)
Boresonic inspections Rotor location
Rotor serial number
Unit installation
Inspection date
Inspection recommendation interval
Next inspection due
Fasteners Stretches
Replacements
Main steam lead flange
thickness
Flange location
Flange readings
Minimum allowable thickness
Piping and uniquely tracked
component inspections
Location
Design information
Inspection dates
Recommended next inspection
Parts used Part description
Identification (Stock/part number)
Quantity used
Test results Hydrogen consumption
Indices
Comparison plots
Megger readings
Resistance readings
HIPOT pass/fail results
Startup Vibration data
Rotor criticals
Shot log
Balance data sensitivity, high spot, etc.
Overspeed test data

9-7
Table 9-2 (cont.)
Recommendations Component identification
Source of recommendation
Description for recommendation
Recommendation
Action required
Task assignment and completion date
Completion information
Purchase orders PO # and description
Vendor
Bid
Final PO amount
Work force Estimated hours
Actual hours expended
Budget Original amount
Actual spent
9.2 Documentation for Vendor Signoff
The job, project, and service are not only comprised of activities but also the documentation of
those activities. The obvious activities that should be contained within the purchasing document
are work scope and compliance with specifications. But there are times when a vendor borrows
equipment, supplies, or other items from the utility. The purchasing document should clearly
outline how borrowed items are accounted for, returned, and billed if necessary. The vendor
signoff and final authorization of payment should be hinged with a signoff for return of all
borrowed items and accounting for items supplied by the plant outside the scope as outlined
within the purchasing document.
Often, the only record required for the purchase order activity is the acknowledgement and
submission of timesheets or completion signoff. The content of the completion record is often
left undescribed and not tied into the purchasing document. Therefore, the historical record or
final report of the activities performed may be left blank.
The purchase order should not only include all the description and technical specifications to
complete the job, but it should also contain the requirements for the final report. The
requirements can include format, delivery schedule, and payment retention. Each purchased
outage activity should be evaluated according to the need and complexity of the report required.
For example, a comprehensive report would be required if technical direction were hired to

9-8
support the outage. Compare this to a machining activity on the turbine where the record of sizes
could be contained in the technical direction report.
Therefore, three purchasing document items have been described for signoff or authorization of
job completion and final payment:
Timesheets or documentation of work completed
Documentation of return of borrowed items
Acceptance of final report
9.3 Issues to Review for Future Planning
Each outage should be entered with a plan to obtain some additional information about the
turbine-generator. The more information known about the turbine-generator components, the
more information can be used in the planning process. Knowing part and machine internal
information can help in planning for part/component replacements and future modifications prior
to the next outage. Therefore, obtaining information about the machine can help in planning for
the upcoming outage and can be used in conjunction with outage reports that provide information
concerning what went on during the outage and recommendations for the future.
Table 9-3 presents a listing of information that can be obtained during an outage and some
possible uses for this information with regard to preparing for the next outage.
Table 9-3
Uses for Engineering Information Obtained in the Outage
Component Information Use
Steam path Number of partitions
Partition shape
Radial height
Pitches
Throats
Outer and inner sidewall
Contour gauge
prefabrication
Partition coupon
prefabrication
Repair specification
preparation
Body Weight
Outside diameter
Packing bore
Set back
Seal face
Ring thickness
Appendage
Total width
Machining information
Seal face inserts
Coating information
(diaphragm size being
worked with)
Diaphragm
Hook fits Dimensions Repairs

9-9
Table 9-3 (cont.)
Coupling Number of holes
Bore diameter
Counter bore diameter and
length
OD
Rabbet dimensions
Bolt replacement
Coupling bolt hold
machining
Journal Diameter
Required length
Machining
Packing Seal configuration Machining
Dovetails Geometry Machining
Buckets Number per row
Type of closure
Tip diameter
Vane root diameter
Vane width
Radial seal platform diameter
Axial seal
Cross key diameter
Vane geometry
Replacements
Machining
Covers Grouping
Width
Thickness
Diameter
Fox holing
Repairs
Material

Rotor
Bore Length
Diameter
Transition
Inspection
Machining
Fits Position
Width
Machining
Diaphragm seal face
inserts
Shells
Packing head or
casing
Dimensions Repairs

9-10
Table 9-3 (cont.)
Bearings Size
Length
Type
Repairs Standard
Oil deflectors Number of teeth
Tooth material ID
Number of teeth per deflector
Repairs
Parts Quantities
Confirmation
Changes
Redesign
Part number
Replacements
Pictures Horizontal joints
Diaphragms
Rotors
Buckets
Assembly
Component orientation
Coupling Number of holes
Bore diameter
Counter bore diameter and
length
OD
Rabbet dimensions
Bolt replacement
Coupling bolt hole
machining
Journal Diameter
Required length
Machining
Hydrogen seals Rotor diameter Replacement parts
Windings Dimensions Replacement parts
Wedges Dimensions Replacement parts
Collector rings Diameter Repair
Replacements
Field
Bore Length
Diameter
Transition
Inspection
Machining

9-11
9.4 Recommendations for Planning Future Outages
Any recommendations for action to be taken during future outages should address the following
issues:
1. Condition assessment of the component
2. Basis for the recommendation
3. Expected action
a. Replacements
b. Repairs
4. Utility history or experience
5. Industry trends
The EPRI-developed Turbo-X computer program, Product Number 1001074, can aid personnel
in the electric power industry by providing a decision analysis tool that combines engineering,
economic, and risk analysis methods to optimize turbine-generator maintenance and inspection
activities.
The joint Program 65/NSTI Guide on Steam Turbine Generator Upgrade/Lessons Learned,
1011678, [62] was produced in 2005 as a web-based information repository. Information
contained in this database was collected during 2005 from a series of plant visits/interviews and
technical advisory group meetings, and focuses on lessons learned while performing steam
turbine upgrades and the process for planning and executing steam turbine upgrades. This is a
living database that allows members to contribute additional information following its release.
Identification of the location of concern and priority of response are also critical information that
should be included in a recommendation. Section 9.4.1 is an example of a detailed description of
a problem, and the corresponding solution is in Section 9.4.2.
9.4.1 Problem Description
The thrust bearing assembly was fully disassembled, inspected, and cleaned. The ball was blue
contact checked, with 80% on the lower half and about the same on the upper half. The pinch
check indicated 2 mils pinch (0.0508 mm) with a 3 mil (0.0762 mm) shim installed in the ring
joint to produce the desired 12 mils (0.0254-0.0508 mm) loose. The torque check of the ball
with the 3 mil (0.0762 mm) shim in the ring joint was 1800 ft/lb (2440 Nm). Note: The 3 mil
(0.0762 mm) shim has been used on the horizontal joint, one on each side of the ring joint for
several years to compensate for the tight pinch of the ball.
The active generator end thrust plate was found with babbitt disbonding. The plate was replaced
with a new one from plant stores. To use the new plate, the thermocouple holes were drilled and
matched from the old plate to the new. Since the new plate was thicker than the old plate, the
steel shim was ground down to obtain the design bearing oil clearance.

9-12
9.4.2 Solution
Order a new spare generator end thrust plate for a spare for the upcoming unit major inspection
to replace the spare generator end plate that was used this outage. With the bearing problems that
have been present for some time in this station from static electrical charges in the LP sections,
which are continually damaging bearings, it is advisable to have both a spare turbine and a
generator end thrust plate on hand for the upcoming unit major inspection.
9.5 Inventory Decision Making
The following is a listing of information that is helpful when reviewing whether a part should be
stocked:
All locations where the part is used
Historical quantity actually used per year
Lead time
Off the shelf
Just in time
Long lead time
Purchase before outage, for outage [direct purchase, outage consumable]
Internal response time
Identification of need
Purchasing
Tracking
Receiving
Delivery
Shelf life
Impact on outage
Use
Outage
Non-outage
Cost
Item cost
Shipping cost [expedited, non-expedited]
Feedback

9-13
The data to be reviewed are primarily for the components either stocked or to be removed from
stock in the utility warehouse. That information should be part of a master turbine-generator
parts database. All parts identified associated with the turbine-generator and auxiliary equipment
should be included in the master parts database. A unique identifier within the database identifies
those parts that are part of warehouse stock.
The review begins with the items currently stocked. The sequence of review can begin with:
Items that have not been used in x number of years
Sequentially looking at each stocked item
Parts associated with a specific piece of equipment
Other systematic approaches
It is easiest to review all the pertinent data at one time. Spreadsheets and other forms of listed
data may be helpful, but they may also not provide enough of the right information in the right
location at the right time. Database forms can link information from various database tables and
provide the critical part review information in one location. They can also provide quick links to
additional part user and supplier information.
The obvious advantage of stocking reviews is the potential reduction in inventory cost because
parts are removed from stock that are infrequently used or no longer used. The potential down
side of removing parts from stock is not having them when needed. The review process has to be
accurate and flexible, parts may be:
Removed
Increased in quantity
Decreased in quantity
Added
9.6 Integration with Maintenance Management Systems
The maintenance management system (MMS) used to support the outage should have contained
at least the following information:
Unique activity identifier
Equipment and component activity assigned to
Task description
Resources to complete task
Number
Duration

9-14
Sequence
Predecessor
Successor
Priority
Start/end dates
A comprehensive MMS would also include part information (BOMs) and provide cost
information into a financial system.
The post-outage review should include a discussion of:
Pre-outage
Shutdown
Disassembly
Planned work
Inspections and unplanned work
Reassembly
Startup
Included in that discussion should be the topics of:
What worked?
What did not work?
What hour estimates were off and why?
The post-outage activity should include a focused review of the tasks performed during the
outage. Note that not all tasks require review. The review parameters may be set to include a
review of only specific tasks that missed the planning estimate by a fixed percentage. The MMS
plans would be revised from the inputs received during the post-outage review.
The possible revisions to the MMS plan would include:
Resource estimates
Task sequencing and scheduling
Task descriptions
Outage recommendations can also be reviewed and entered into the MMS system to support the
standard outage plan or to create individual one-time-only activities.
U.S. nuclear plants are implementing preventive maintenance (PM) tasks with little documented
basis to support the tasks and their intervals. The EPRI report Preventive Maintenance Basis

9-15
Database Client Server, Version 6.0, 1009584, [53] provides utilities with PM information for a
number of components. Tasks within the guide are divided according to three categories:
Condition monitoring - to measure the progression toward failure so that the corrective action
can be planned or indicated
Time-directed - to prevent failure by performing scheduled maintenance
Failure finding - to identify a failed condition so that corrective maintenance can be initiated
10-1
10
REFERENCES
1. Turbine Steam Path Damage: Theory and Practice. EPRI, Palo Alto, CA: 1999.
TR-108943-V1 and V2.
2. EHC Tubing/Fittings and Air Piping Applications and Maintenance Guide. EPRI, Palo Alto,
CA: 2000. 1000935.
3. Electrohydraulic Control (EHC) Fluid Maintenance Guide. EPRI, Palo Alto, CA: 2002.
100554.
4. General Electric Electrohydraulic Controls (EHC) Electronics Maintenance Guide. EPRI,
Palo Alto, CA: 1997. TR-108146.
5. Steam Turbine Hydraulic Control System Maintenance Guide. EPRI, Palo Alto, CA: 1996.
TR-107069.
6. Crane Maintenance and Application Guide: Maintenance and Application of Overhead
Cranes. EPRI, Palo Alto, CA: 2000. 1000986.
7. Compressed Air System Maintenance Guide. EPRI, Palo Alto, CA: 2002. 1006677.
8. Foreign Materials Exclusion Guidelines, Revision 1. EPRI, Palo Alto, CA: 2005. 1009709.
9. K. C. Cotton. Evaluating and Improving Steam Turbine Performance, 2nd Edition. Cotton
Fact, Inc., Rexford, NY, 1998.
10. Infrared Thermography Guide, Revision 3. EPRI, Palo Alto, CA: 2002. 1006534.
11. System and Equipment Troubleshooting Guideline. EPRI, Palo Alto, CA: 2002. 1003093.
12. Feedwater Pump Turbine Controls and Oil System Maintenance Guide. EPRI, Palo Alto,
CA: 2001. 1003094.
13. Guidelines for Using Synthetic Slings for Lifting and Rigging. EPRI, Palo Alto, CA: 2003.
1007676.
14. Machinerys Handbook, 26th Print Edition, Fasteners, Table 2: Accuracy Bolt Preload
Application Methods. Industrial Press, 2000.
15. Guidelines for Reducing the Time and Cost of Turbine-Generator Maintenance Overhauls
and Inspections: Volume 3, Balancing and Alignment. EPRI, Palo Alto, CA: 2003. 1008856.
and Inspections: Volume 3, TGAlign Computer Program Version 2.0 Users Manual
(English Units Version). EPRI, Palo Alto, CA: 2003. 1008827.
and Inspections: Volume 3, TGAlign Computer Program Version 1.0 Users Manual (SI
Units Version). EPRI, Palo Alto, CA: 2002. 1007537.

References
10-2
18. Demonstration of a Videoprobe Delivery Device for In Situ Inspection of Steam Turbine and
Combustion Turbine Machines. EPRI, Palo Alto, CA: 2002. 1004002.
19. Interim Guidelines for In Situ Visual Inspection of Inlet and Outlet Turbine Stages: Part 2:
Experiences, Approaches, and Improvements in Remote Visual Inspection. EPRI, Palo Alto,
CA: 2000. TR-114961.
and Inspections: Volume 6, High-Pressure/Intermediate-Pressure Blade/Disk Design Audit
and Inspection Procedures. EPRI, Palo Alto, CA: 2001. 1006087.
and Inspections: Volume 7, Low-Pressure Blade/Disk Design Audit and Inspection
Procedures. EPRI, Palo Alto, CA: 2001. 1006088.
22. NDE Guidelines for Fossil Power Plants. EPRI, Palo Alto, CA: 1997. TR-108450.
23. Remote NDE Technology for Steam Turbines. EPRI, Palo Alto, CA: 2002. 1006814.
24. Rotor Boresonic Inspection Guidelines. EPRI, Palo Alto, CA: 1990. NP-6742-L.
25. NEI Parsons Ltd. Boresonic Inspection System Evaluation. EPRI, Palo Alto, CA: 1993. TR-
102126.
26. Northeast Inspection Services, Inc. Boresonic Inspection System Evaluation. EPRI, Palo
Alto, CA: 1993. TR-102256.
27. WesDyne International UDRPS Boresonic Inspection System Evaluation. EPRI, Palo Alto,
CA: 1996. TR-106234.
28. General Electric Company Boresonic Inspection System Evaluation. EPRI, Palo Alto, CA:
1997. TR-107174.
29. Reinhart & Associates, Inc. Boresonic Inspection System Evaluation. EPRI, Palo Alto, CA:
1997. TR-108423.
30. Boresonic System Performance Guide. EPRI, Palo Alto, CA: 1994. TR-104355.
31. Guide for In-Service Ultrasonic Inspection of Boreless Turbine Rotors and Other Solid
Shafts. EPRI, Palo Alto, CA: 1992. TR-101836.
32. Inspection of Turbine Disk Blade Attachment Guide: Volume 1, Background and Inspection
Principles. EPRI, Palo Alto, CA: 1994. TR-104026-V1.
33. Steam Turbine Disk Blade Attachment Inspection Using Linear Phased Array Ultrasonic
Technology. EPRI, Palo Alto, CA: 2000. 1000122.
34. Field Application for Ultrasonic Linear Phased Array Inspection of Straddle-Mount and
Axial-Entry Disk Blade Attachments. EPRI, Palo Alto, CA: 2000. 1000663.
35. Evaluation of Nonmagnetic Generator Retaining Rings. EPRI, Palo Alto, CA: 1994. TR-
104209.
36. Reducing Solid Particle Erosion Damage in Large Steam Turbines, GER-3478A, presented
by W.J. Sumner, et al. at the 1985 American Power Conference.

References
10-3
37. Guide for On-Line Testing and Monitoring of Turbine Generators. EPRI, Palo Alto, CA:
2002. 1006861.
38. Testing of Stator Windings for Thermal Aging: Interim Results. EPRI, Palo Alto, CA: 2002.
1004557.
39. Assessment of Partial Discharge and Electromagnetic Interference On-Line Testing of
Turbine Driven Generator Stator Winding Insulation Systems. EPRI, Palo Alto, CA: 2003.
1007742.
40. Conversion to Deaerated Stator Cooling Water in Generators Previously Cooled w/ Aerated
Water: Interim Guidelines. EPRI, Palo Alto, CA: 2000. 1000069.
41. Guidelines for Detecting and Removing Flow Restrictions for Water-Cooled Stator
Windings. EPRI, Palo Alto, CA: 2002. 1004704.
42. Generator Cooling System Operating Guidelines: Cooling System Maintenance and
Performance Guidelines During Start-Up, Operation, and Shutdown. EPRI, Palo Alto, CA:
2002. 1004004.
43. Experience with Limited Access Generator Inspections: A Study of Inspections Done with
Robotic Equipment and their Effectiveness as Compared with Conventional Inspections
Where the Generator Rotor Is Removed. EPRI, Palo Alto, CA: 2000. 1000100.
44. On-Line Detection of Shorts in Generator Field Windings. EPRI, Palo Alto, CA: 1999. TR-
114016.
45. Tools to Optimize Maintenance of Generator Excitation System, Voltage Regulator, and
Field Ground Protection. EPRI, Palo Alto, CA: 2002. 1004556.
46. Power Plant Electrical Reference Series: Volume 1, Electrical Generators. EPRI, Palo Alto,
CA: 1987. EL-5036-V1.
47. Military Standard System Safety Program Requirements, Department of Defense, January
1993. MIL-STD-882C.
48. ORBIT, March 1993, Vol. 14, No.1, p. 9.
49. D.P. Timo, General Electric Nuclear SCC Experience, EPRI Seminar on Steam Turbine
Disk Integrity, San Antonio, Texas, December 1983.
50. Steam Turbine Disk Brittle Failure: Influencing Parameters and Probabilistic Analysis
Demonstration. EPRI, Palo Alto, CA: 2002. 1003264.
51. Aerospace Recommended Practice, Society of Automotive Engineers, ARP-598A.
52. Shaft Alignment Guide. EPRI, Palo Alto, CA: 1999. TR-112449.
53. Preventive Maintenance Basis. EPRI, Palo Alto, CA: 1998. TR-106857.
54. SAFER-PC Release 2.2. EPRI, Palo Alto, CA: 2006. 1013044.
55. Ultrasonic Inspection of Steam Turbine Blade Roots. EPRI, Palo Alto, CA: 2005. 1011680.
56. Axial Entry Blade Attachment NDE Performance Demonstration. EPRI, Palo Alto, CA:
2005. 1011677.

References
10-4
57. Evaluation of Replacement Interstage Seals for Turbine Upgrades. EPRI, Palo Alto, CA:
2005. 1010214.
58. Evaluation Tool for Cost Effective Steampath Upgrades. EPRI, Palo Alto, CA: 2006.
1004565.
59. Condition Assessment Technology for Steam Valves. EPRI, Palo Alto, CA: 2005. 1010211.
60. Excitation System Retrofit and Replacement-Lessons Learned. EPRI, Palo Alto, CA: 2006.
1011675.
61. Generator Rotor Shaft Cracking Management Guide. EPRI, Palo Alto, CA: 2005. 1011679.
62. Guide on Steam Turbine Generator Upgrade/Lessons Learned. EPRI, Palo Alto, CA: 2005.
1011678.

A-1
A
CONDITION ASSESSMENT DATA SHEETS
Presented in this appendix are 17 data sheet sets referenced in the discussion of an in-service
condition assessment of a steam turbine-generator unit. Generally, each of the sets consists of
three parts. The first provides a summary of available data collected from the system as a whole
or from individual sections. The second sheet supplements the first by means of an interview
with the specialist, engineer, or operator directly responsible for maintaining and monitoring the
system. The third sheet summarizes an assessment of the present condition of system based on
the information obtained from the data audit and the interview.
Data Sheet #1 provides an overall review and assessment of the maintenance history for the unit.
Data Sheets #2 through #14 repeat the data audit, interview, and condition assessment process
for each of the major systems found in the turbine-generator unit:
Turbine generation vibration
Bearing metal and oil temperatures
Section performance parameters
Start-up operation
Steam purity
Lubricating oil and EHC analysis
Pump start test results
Valve tightness test results
Turbine trips
Turbine monitoring instrumentation
Auxiliary system operation
Visual inspection
Generator-exciter condition
Data Sheet #15 is a checklist of 69 out-of-limit indicators to highlight potential problems or
issues. Data Sheet #16 is a summary of the long-range maintenance plans for the individual
systems, sections, and components included within the individual audits.
Data Sheet # 17 is the summary of the information obtained and reviewed in the preceding series
of documents. It provides a one-page synopsis that lists the components/systems and ranks their
present condition.

Condition Assessment Data Sheets
A-2
Table of Data Sheets
Data Sheet #1: (a) Maintenance History Summary (Page 1 of 4) ................................................4
Data Sheet #1: (b) Modifications and Upgrades (Page 2 of 4).....................................................5
Data Sheet #1: (c) Forced Outage Issues and Root Causes (Page 3 of 4)..................................6
Data Sheet #1: (d) Potential Risk for Component Failure (Page 4 of 4).......................................7
Data Sheet #2: (a) Turbine-Generator Vibration Audit (Page 1 of 3) ...........................................8
Data Sheet #2: (b) Turbine-Generator Vibration Interview (Page 2 of 3) .....................................9
Data Sheet #2: (c) Turbine-Generator Vibration Assessment (Page 3 of 3) ..............................10
Data Sheet #3: (a) Bearing Metal and Oil Temperature Audit (Page 1 of 3) ..............................11
Data Sheet #3: (b) Bearing Metal and Oil Temperature Interview (Page 2 of 3) ........................12
Data Sheet #3: (c) Bearing Metal and Oil Temperature Assessment (Page 3 of 3) ...................13
Data Sheet #4: (a) Performance Information Audit (Page 1 of 3) ..............................................14
Data Sheet #4: (b) Performance Information Interview (Page 2 of 3) ........................................15
Data Sheet #4: (c) Performance Information Assessment (Page 3 of 3)....................................16
Data Sheet #5: (a) Start-Up Operation Audit (Page 1 of 3)........................................................17
Data Sheet #5: (b) Start-Up Operation Interview (Page 2 of 3)..................................................18
Data Sheet #5: (c) Start-Up Operation Condition Assessment (Page 3 of 3).............................19
Data Sheet #6: (a) Steam/Water Purity Monitoring (Fossil) Audit (Page 1 of 3).........................20
Data Sheet #6: (b) Steam Purity Monitoring Interview (Page 2 of 3)..........................................21
Data Sheet #6: (c) Steam Purity Monitoring Condition Assessment (Page 3 of 3).....................22
Data Sheet #7: (a) Lube Oil and EHC Analysis Audit (Page 1 of 3)...........................................23
Data Sheet #7: (b) Lube Oil and EHC Analysis Interview (Page 2 of 3).....................................25
Data Sheet #7: (c) Lube Oil and EHC Condition Assessment (Page 3 of 3) ..............................26
Data Sheet #8: (a) Pump Start Test Results Audit (Page 1 of 3) ...............................................27
Data Sheet #8: (b) Pump Start Interview (Page 2 of 3)..............................................................28
Data Sheet #8: (c) Pump Condition Assessment (Page 3 of 3) .................................................29
Data Sheet #9: (a) Valve Tightness and Test Results Audit (Page 1 of 3).................................30
Data Sheet #9: (b) Valve Tightness and Test Results Audit (Page 2 of 3).................................31
Data Sheet #9: (c) Valve Tightness Condition Assessment (Page 3 of 3) .................................32
Data Sheet #10: (a) Turbine Trip Test Results Audit (Page 1 of 3)............................................33
Data Sheet #10: (b) Turbine Trip Interview (Page 2 of 3) ..........................................................34
Data Sheet #10: (c) Turbine Trip Interview (Page 3 of 3) ..........................................................35
Data Sheet #11: (a) Turbine Instrumentation Survey Results Audit (Page 1 of 4) .....................36
Data Sheet #11: (b) Turbine Instrumentation Survey Interview (Page 3 of 4) ............................38
Data Sheet #11: (c) Turbine Instrumentation Condition Assessment (Page 4 of 4) ...................39
Data Sheet #12: (a) Generator-Exciter Inspection Audit (Page 1 of 3) ......................................40
Data Sheet #12: (b) Generator-Exciter Inspection Interview (Page 2 of 3) ................................41
Data Sheet #12: (c) Generator-Exciter Condition Assessment (Page 3 of 3).............................42

A-3
Data Sheet #13: (a) Auxiliary System Operating Information Audit (Page 1 of 3) ......................43
Data Sheet #13: (b) Auxiliary System Information Interview (Page 2 of 3).................................44
Data Sheet #13: (c) Auxiliary System Condition Assessment (Page 3 of 3) ..............................45
Data Sheet #14: (a) Visual Inspection Audit (Page 1 of 3).........................................................46
Data Sheet #14: (b) Visual Inspection Interview (Page 2 of 3)...................................................47
Data Sheet #14: (c) Visual Inspection Condition Assessment (Page 3 of 3)..............................48
Data Sheet #15: (a) Checklist of Out-of-Limit Events and Conditions (Page 1 of 4) ..................49
Data Sheet #15: (a) Checklist of Out-of-Limit Events-Conditions (Page 4 of 4) .........................52
Data Sheet #15: (b) Condition Assessment for Out-of-Limit Events (Page 1 of 1) .....................53
Data Sheet #16: (a) Current Long-Range Maintenance Plan for Unit (Page 1 of 3)...................54
Data Sheet #16: (b) Current Long-Range Maintenance Plan for Unit (Page 2 of 3)...................55
Data Sheet #16: (c) Current Long-Range Maintenance Plan for Unit (Page 3 of 3)...................56
Data Sheet #17: (a) Overall Unit Condition Assessment Form..................................................57

A-4
Data Sheet #1: (a) Maintenance History Summary (Page 1 of 4)
Plant and Unit Number:
Unit OEM:
Design Rating: (MW) Commercial Operation Date:
Unit MDC: (MW) Date Last Inspected:
MAINTENANCE HISTORY SUMMARY
Chronic
Problems
Date Component Inspected Recommendations
Yes No

A-5
Data Sheet #1: (b) Modifications and Upgrades (Page 2 of 4)
Unit OEM:
MODIFICATIONS AND UPGRADES MADE TO IMPROVE PERFORMANCE OR RELIABILITY
Date Type of Upgrade (Describe) Performance or Reliability Improvement
(Identify Which)

A-6
Data Sheet #1: (c) Forced Outage Issues and Root Causes (Page 3 of 4)
Unit OEM:
SIGNIFICANT FORCED OUTAGE ISSUES AND ROOT CAUSES
Date of
Forced
Outage
Part/Component
Involved
Summary of Root Cause Responsible for Outage

A-7
Data Sheet #1: (d) Potential Risk for Component Failure (Page 4 of 4)
Unit OEM: Date:
COMPONENTS HAVING HIGH RISK OF FAILURE PRIOR TO NEXT OUTAGE
Potential Risk of Failure Based on Past Maintenance History
Component
High Medium Low

A-8
Data Sheet #2: (a) Turbine-Generator Vibration Audit (Page 1 of 3)
Unit OEM: Date of Audit:
Unit MDC: (MW) Date of Last Inspection
TURBINE-GENERATOR VIBRATION AUDIT
Minimum Load Vibration Full Load Vibration
X Y X Y
1
st
Critical
Vibration
2
nd

Critical
Vibration
Location
of Pickup
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F
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V
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P
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P
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F
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c
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o
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P
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Notes:
At minimum load and at full load, a frequency scan from 1x through 10x speed range should be recorded and attached to this sheet.
Bode plots should be run if instrumentation is available. These aid in accurately locating the critical speed amplitudes and phase
angles.
Attach to this sheet a copy of roll-up and roll-down vibration if available.

A-9
Data Sheet #2: (b) Turbine-Generator Vibration Interview (Page 2 of 3)
Unit OEM: Date of Interview:
Design Rating: (MW) Date Last Inspected:
Unit MDC: (MW) Commercial Operation Date:
TURBINE-GENERATOR VIBRATION - OPERATOR INTERVIEW
No. 1 Does the turbine-generator frequently run in alarm? If so, which bearing?
No. 2 Does the turbine/generator or exciter have high vibration alarms during roll-up, roll-down or at
minimum or full load? At what bearings do these alarms occur, and what speed does it occur?
No. 3 Has the unit experienced many vibration trips since the last overhaul? If so, how many? What
bearing caused the trip, and how high was the vibration during the subsequent roll down?

No. 4 Was there suspected damage due to high vibration during roll down to turning gear? Where do
you think the damage occurred?
No. 5 Have there been any step changes in vibration at any bearing? If so, what was the amplitude
change that occurred?

No. 6 Have any operation changes (vibration, pressure, temperature, steam flow, efficiency, etc.)
occurred since the high vibration event?
No. 7 What do you think the risk is (High, Medium, Low) for a failure given the above suspected
damage?

No. 8 What are the vibration alarm and trip values for this unit? Are they based on filter-out or filter-in
vibration?

A-10
Data Sheet #2: (c) Turbine-Generator Vibration Assessment (Page 3 of 3)
Unit OEM:
Date of Assessment:
Design Rating: (MW)
Date Last Inspected:
Unit MDC: (MW)
Commercial Operation Date:
ASSESSMENT OF CURRENT TURBINE-GENERATOR VIBRATION CONDITION
(BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence If
Condition Is
Allowed to
Continue As Is
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Recommended Actions or
Contingencies That Might Be
Taken to Further Verify or
Correct Potential Problem

FAILURE: Breakdown of the component or system to the point where it would force an outage.
RISK: How certain do you feel that this may be a problem?
ACTION: Immediate: Hours or days Intermediate: 312 months Long Term: Next outage

A-11
Data Sheet #3: (a) Bearing Metal and Oil Temperature Audit (Page 1 of 3)
BEARING METAL AND BEARING OIL TEMPERATURE AUDIT
Bearing Metal Oil Temperatures
At Maximum
Load
At Minimum
Load

Comments
Bearing
Number
At
Maximum
Load
At
Minimum
Load
Oil
Inlet
Oil
Outlet
Oil
Inlet
Oil
Outlet

A-12
Data Sheet #3: (b) Bearing Metal and Oil Temperature Interview (Page 2 of 3)
BEARING METAL AND OIL TEMPERATURE CONDITION OPERATOR INTERVIEW
No. 1 Have any bearings exceeded 220F (104C)? If so, did any other bearing metal temperatures rise
after this occurred? (Identify bearing no. ___: from ___ degrees to ____degrees.)

No. 2 Did unit vibration increase after the above temperature spike occurred? If so, at what bearing and
what was the vibration amplitude? (Identify bearing no. ____; Amplitude ______.)

No. 3 During the roll to speed or during a shutdown, has bearing vibration increased since the above
event? If so, at what bearing? What is the new vibration during the roll down or roll to speed?
(Identify bearing no. ___; New vibration _________.)

No. 4 Has anything other than the above occurred that you would consider being abnormal? (Identify.)

A-13
Data Sheet #3: (c) Bearing Metal and Oil Temperature Assessment (Page 3 of 3)
Unit OEM: Date of Assessment:
ASSESSMENT OF CURRENT BEARING CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence If
Condition Is
Allowed to
Continue As Is
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Correct Potential Problem


A-14
Data Sheet #4: (a) Performance Information Audit (Page 1 of 3)
PERFORMANCE INFORMATION AUDIT (AT FULL LOAD VALVES WIDE OPEN)
Performance Parameter Measured
Value
Measured
Value (Last
Assessment)
Deviation Comments
Main steam flow - lbs/hr
Throttle pressure - psia
Throttle temperature - F
First stage pressure - psia
First stage temperature - F
HP exhaust pressure - psia
HP exhaust temp - F
IP inlet pressure psia
IP inlet temperature - F
LPA inlet pressure - psia
LPA inlet temp - F
LPA backpressure in. Hg
LPB inlet pressure - psia
LPB inlet temp - F
LPB backpressure in. Hg
LPC inlet pressure psia
LPC inlet temp - F
LPC backpressure in. Hg
HP efficiency
IP efficiency
LPA efficiency
LPB efficiency
LPC efficiency
HP throttle flow factor
IP throttle flow factor
LPA throttle flow factor
LPB throttle flow factor
LPC throttle flow factor

A-15
Data Sheet #4: (b) Performance Information Interview (Page 2 of 3)
PERFORMANCE SPECIALIST/ENGINEER INTERVIEW
No. 1 Has there been any significant change in section efficiencies since the last turbine overhaul or last
condition evaluation of the unit? In what section did it occur and when?

Regarding the following performance parameters, determine what changes have occurred since the
last inspection or CA interview: (Note timing that should be identified as either Abrupt or Gradual.)
PARAMETER FROM TO % CHANGE TIMING
(a) Steam flow
(b) Throttle pressure
(c) First stage pressure
(d) Hot reheat pressure
(e) LP inlet pressure
(f) HP efficiency
No. 2
(g) IP efficiency
No. 3 Did any of the above changes occur after any significant operating event on the unit? (Significant
events in this case can be a sudden change in turbine vibration while at load, a full load trip, a high
vibration during roll up or roll down, or a significant boiler/reactor water or steam chemistry upset.)

No. 4 Did any of the above changes occur after the feedwater heater level control problems, sudden
opening of attemperator sprays, or other issues where the rotor and casing could have been
thermally quenched?

A-16
Data Sheet #4: (c) Performance Information Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT PERFORMANCE CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition Is
Allowed to
Continue As Is
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Correct Potential Problems


A-17
Data Sheet #5: (a) Start-Up Operation Audit (Page 1 of 3)
Check Which Applies to Unit
Type of Operation
Base Load 80% or
Higher
Cycling Frequent Start/Stop
SUMMARY OF START-STOP OPERATING HISTORY
Type of Start HP IP LPA LPB LPC GEN EXC
No. of cold starts
No. of hot starts
No. of warm starts
No. service hours
Run to speed w/o
synchronizing

No. trips at 75%
load or higher

Since Last
Inspection
No. trips at 75%
load or lower

No. of cold starts
No. of hot starts
No. of warm starts
No. service hours
No. trips at 75%
load or higher

No. trips at 75%
load or lower

Since
Commercial
Operation
Run to speed w/o
synchronizing

A-18
Data Sheet #5: (b) Start-Up Operation Interview (Page 2 of 3)
START-UP OPERATION INTERVIEW (ABNORMAL EVENTS)
No. 1 Has the unit experienced situations where it operated outside the frequency range recommended by
the OEM? How many times did this occur? For how many total hours has this occurred for this unit?

No. 2 Has the unit had problems with synchronizing out of phase with the grid? If so, how many times has
this occurred? Do you recollect approximately how many degrees out of phase these were on
average?

No. 3 Has the unit operated for any significant time at 5 inches Hg backpressure or higher? For how many
hours did this occur since the last overhaul?

No. 4 Have there been any line switching events on the system that caused changes in normal operating
parameters such as vibration? How many times has this occurred? What was the extent of the
vibration change?

No. 5 Has the machine run for any significant time where three phase line voltage differences exceeded
OEM recommendations? How many times did this happen? What was the estimated cumulative
total time in hours?

No. 6 Has the unit operated where generator dew point exceeded OEM recommendations? For how many
hours?

No. 7 Since the last overhaul, has the unit experienced water induction or similar events causing high
vibration on the unit? How many times did this occur? How high was the vibration?

No. 8 Have there been any other abnormal operating events on the unit that affected performance or the
method in which the unit is operated? Please explain?

A-19
Data Sheet #5: (c) Start-Up Operation Condition Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT PERFORMANCE CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition
Allowed to
Continue As Is
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A-20
Data Sheet #6: (a) Steam/Water Purity Monitoring (Fossil) Audit (Page 1 of 3)
Check Which Applies to Unit
Type of water
treatment
EPT - Equilibrium phosphate
treatment
CT - Caustic treatment
PT - Phosphate treatment OT - Oxygenated treatment
AVT - All volatile treatment
SUMMARY OF STEAM/WATER PURITY MONITORING HISTORY
Specify Frequency of Each Test at the Following Locations:
C = continuous, O = on-line, G = grab sample daily,
W = grab sample weekly
Test Type
Polisher Outlet or
Economizer Inlet
Main Steam or
Reheat Steam
Condensate
Pump Discharge
Other: (Blow Down,
Treated Makeup)
Specific conductivity
Cation conductivity
Sodium
Chlorides
Silica
pH
Typical Steam Limits in Fossil Plants
Parameter Monitored
EPT, AVT, OT PT CT
Plant Criteria
Sodium - Na 3 ppb 5 ppb 2 ppb
Chlorine - Cl 3 ppb 3 ppb 2 ppb
Sulfate (SO4) 3 ppb 3 ppb 2 ppb
Cation conduct. < 0.15 < 0.3 < 0.3
Silica - SiO2 10 ppb 10 ppb 10 ppb
Total organic carbon - TOC 100 ppb 100 ppb 100 ppb
Feedwater chemistry limits AVT (mixed
metallurgy)
AVT (all ferrous) Oxygenated treatment
pH @ 25C 8.89.1 9.29.6 8.08.5 (once through) 9.0-9.5 (drum)
Ammonia (ppm) 0.15 to 0.4 0.52.0 0.020.07 (once through) 0.3 -1.5 (drum)
Cation conductivity (uS/cm) < 0.2 to <0.15 < 0.2 to < 0.1 < 0.15
Fe (ppb) < 10 to < 5 (drum) < 5 to < 2(drum) < 5 to < 1 (drum)
Cu (ppb) < 2 < 2 < 1
Oxygen (ppb) <5 to< 2 (drum) 1 to 10 (once thru) 30-150 (once through) 3050 (drum)
SUMMARY OF OUT-OF-LIMIT CONDITIONS
Purity
Parameter
Extent Criteria
Exceeded
How Long
Exceeded
How Was It
Resolved
Potential Impact on Turbine

A-21
Data Sheet #6: (b) Steam Purity Monitoring Interview (Page 2 of 3)
STEAM/WATER PURITY INTERVIEW
No. 1 Have there been any steam or water purity problems that could result in deposits or corrosion
products being deposited in the turbine?

No. 2 How long did these events occur (hours, days weeks)? Have they been corrected?
No. 3 Have there been any significant condenser tube leaks that affected steam or water purity limits?

No. 4 Have there been any performance changes in the turbine that could be associated with the
steam/water purity limits being exceeded?

A-22
Data Sheet #6: (c) Steam Purity Monitoring Condition Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT STEAM/WATER CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence If
Condition Is
Allowed to
Continue As Is
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A-23
Data Sheet #7: (a) Lube Oil and EHC Analysis Audit (Page 1 of 3)
LUBE OIL TEST RESULTS
Lube Oil Acceptance Criteria
Oil
Sample
Location
510
Microns
128,000
ppm*
1025
Microns
42,000
ppm
2550
Microns
6,500
ppm
50100
Microns
1,000
ppm
100250
Microns
92 ppm
> 250
Microns
None
Water %
1,000
ppm
Neutrality
Number

Color
From
main oil
tank

Other:
specify

From
bearing
header

* All ppm designations here are per a 100-milliliter fluid sample size.

A-24
Table 11-1 Summary of Operating Limits
EHC Test Results
Parameter
1
EPRI Frequency Reference Achievable
2
Comments
Color Limit of 4.0 max
or monthly
increase of 0.5
Monthly 4.4.3.1 1.5 (Light Tan) ASTM D-1500 Color Criteria; OEMs limits are included in
Appendix H. Fluid Color Scale Comparison Chart is
included in Appendix G5.
Viscosity +/- 10% initial
value
Monthly 4.4.3.2 N/A System contamination measurement most important after
breach of system
Acidity
(mg KOH/g)
< 0.1 Monthly 4.4.3.3 < 0.05
Chlorines
(ppm)
< 50 Quarterly 4.4.3.4 < 10 System contamination measurement most important after
breach of system
Water
(%, ppm)
< 0.1,
1000ppm
Monthly 4.4.3.5 < 0.05,
500ppm
2 main methods for improving this are dry air purge and
vacuum dehydration
Mineral Oil
3

(%)
< 0.5 Quarterly 4.4.3.6 <0.1 System contamination measurement most important after
breach of system
Resistivity
(G-Ohm-cm)
> 5 - 10 Monthly 4.4.3.7 > 20 Can cause erosion problems on stagnant areas of system,
fluid types have different values
Particulate
4
<2K/100 ml
of 5-10
micron
5

Monthly 4.4.3.8 1K/100 ml
of 5-10
micron5
EPRI value is a good starting point for developing fluid
monitoring, but it has to have consistent sample methods
and points
Individual
Metals
(per metal)
< 10 ppm 6 Months 4.4.3.9 < 2 ppm Not a routine check, but indicative of degrading system,
exclude phosporus and chromium. If particulate or acid #s
increase then increase the frequency of metal testing.
Foaming
(Height/Colla
pse time)
< 100 ml/
< 5 minute
12 Months 4.4.3.10 N/A Collapse time is reported as time to get to nil foam height
Air Release < 10 minutes 12 Months 4.4.3.11 < 8 minute Should be performed with the system health check. With
natural fluids < 5 minutes is achieveable.
Hexane Test
6
B8 2 Years 4.4.3.12 B2/B3 Indicator of heat related problems
NOTES:
1. Any one parameter out of the recommended values does not condemn a fluid or system. The collective data is what determines if a fuild or system is of concern. More than
2 parameters outside of the values would require evaluation to determine the total affect. Test methods are specified in Table 4-10 in section 4.4 of EPRI report 1004554.
2. Achievable values normally require system modifications and upgrades.
3. Some standard tests (GE) do not report only mineral oil, but generate a number that includes other non-soapontifiables (fluid degradation by products).
4. If this parameter doubles from one sample to the next then a new sample is needed per the EPRI sample procedure in section 4.2.2 of EPRI report 1004554.
5. ISO cleaniness code equivalent numbers are not available at this time due to changes in calibration test dust and the techniques which had been used in the most previous
testing.
6. Rate according to ASTM D-2276 Appendix A3 B scale for aviation turbine fuels going from B-0 (white) to B-10 (very dark brown to black).

A-25
Data Sheet #7: (b) Lube Oil and EHC Analysis Interview (Page 2 of 3)
LUBE OIL AND EHC ANALYSIS INTERVIEW
No. 1 Has the lube oil water content or particle counts exceeded recommended limits? If so, how long
were the limits exceeded?
No. 2 When was the last time the lube oil was tested by your lube oil supplier? What were the test results?
No. 3 Have there been any problems with the lube oil purification system? What kind of problem, and how
long did they occur?
No. 4 Are there any issues or problems with the lube oil or lube oil system that could cause a forced
outage on this unit?

No. 5 Has the EHC fluid exceeded the above-specified limit? What actions were taken? Did this correct
the problem? If the problem was not corrected, how long has the problem been going on? What is
the plan to correct the problem?
No. 6 Are there any problems with the EHC system that could cause a forced outage? Please describe in
detail?

A-26
Data Sheet #7: (c) Lube Oil and EHC Condition Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT LUBE OIL AND EHC CONDITION
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition Is
Allowed to
Continue As Is
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A-27
Data Sheet #8: (a) Pump Start Test Results Audit (Page 1 of 3)
PUMP START TEST RESULTS
Acceptance/Rejection Pump Type Frequency of
Pump Start Tests
Start Test
Results
Plant
Acceptance
Criteria
Acceptable Unacceptable
DC lube oil pump
Main seal oil pump
Recirculating seal oil
pump

DC seal oil pump
Stator cooling pump
EHC pump
SPOT CHECK OF PUMP PRESSURES
Pump Type Pressure at skid Pressure
after filter
Pressure at
turbine deck
Comments/Issues found
DC lube oil pump
Main seal oil pump H
2

and air side

Recirculating seal oil
pump

DC seal oil pump
Stator cooling pump
EHC pump

A-28
Data Sheet #8: (b) Pump Start Interview (Page 2 of 3)
PUMP START-UP OPERATION INTERVIEW (ABNORMAL EVENTS)
No. 1 How frequently are start tests performed on the pumps noted above?

No. 2 Is a record maintained by plant operations or maintenance personnel of start test results and actions
taken if they did not meet specified criteria? (Review test results.)
No. 3 Have there been any problems noted on the above pumps? What were these problems?
No. 4 Have the above problems been resolved?
No. 5 What PM or PdM is performed on the above pumps? Who is responsible for this work?
No. 6 Briefly review the PM/PdM program for these pumps, and look at work orders used for this effort.
(Review what work is done and the frequency with which it is performed on each pump type.)

No. 7 Have there been any problems noted on the lubrication oil system, seal oil system, stator cooling
system, or EHC system during the course of performing PM/PdM work on these systems that
indicate they may not be operating within OEM expectations? (List all issues and discuss any
concerns.)

A-29
Data Sheet #8: (c) Pump Condition Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT PUMP CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition Is
Allowed to
Continue As Is
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A-30
Data Sheet #9: (a) Valve Tightness and Test Results Audit (Page 1 of 3)
VALVE TIGHTNESS AND OPEN/CLOSE TEST RESULTS
Tightness Test Acceptance Criteria Open/Close Acceptance Criteria
Type of
Valve
Acceptance Criteria
(with Full Pressure
Against Valve)
A
c
c
e
p
t
a
b
l
e

N
o
t

A
c
c
e
p
t
a
b
l
e

Acceptance Criteria
A
c
c
e
p
t
a
b
l
e

N
o
t

A
c
c
e
p
t
a
b
l
e

Control
Valves
If less than 1/6 rated speed:
acceptable.
If greater than 1/2 rated
speed: unacceptable.

No sticking allowed when test is
performed. If sticky, correct at next
weekend shutdown.

Stop
valves
No leakage.
weekend shutdown.

Reheat
Stop
valves
Valve closes.
weekend shutdown.

Intercept
valves
Less than rated speed
whenever closed against
rated reheat pressure.

weekend shutdown.

Non-
return
valves
Valves close when unit is
tripped.
Valve will close when unit is tripped.

A-31
Data Sheet #9: (b) Valve Tightness and Test Results Audit (Page 2 of 3)
VALVE TIGHTNESS INTERVIEW
No. 1 How frequently are valve tightness and valve close tests performed on the unit?

No. 2 Do the specific valves meet the acceptance criteria noted above?

No. 3 Are there any valves noted above that take longer to close now than tests performed earlier to
confirm the valves ability to close when called for by the control system?
No. 4 Does the plant keep track of the time it takes for a valve to close and trend this information in order
to use it as a basis for maintenance inspection?

A-32
Data Sheet #9: (c) Valve Tightness Condition Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT STEAM/WATER CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence If
Condition Is
Allowed to
Continue As Is
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A-33
Data Sheet #10: (a) Turbine Trip Test Results Audit (Page 1 of 3)
TURBINE TRIP TEST RESULTS
Type Test Date
Tested
Acceptable Not
Acceptable
Comments and Recommendations
Overspeed trip
Minimum oil trip
Vacuum trip
Solenoid trip
Thrust trip
Shaft pump trip
Others (list)

A-34
Data Sheet #10: (b) Turbine Trip Interview (Page 2 of 3)
TURBINE TRIP INTERVIEW (ABNORMAL EVENTS)
No. 1 How frequently does the turbine trip off-line?

No. 2 Is a record maintained by plant operations or maintenance personnel of trips and actions taken to
meet specified criteria? (Review test results.)
No. 3 Have there been any problems noted on the above turbines? What were these problems?
No. 4 Have the above problems been resolved?

A-35
Data Sheet #10: (c) Turbine Trip Interview (Page 3 of 3)
ASSESSMENT OF CURRENT TRIP CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition Is
Allowed to
Continue As Is
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A-36
Data Sheet #11: (a) Turbine Instrumentation Survey Results Audit (Page 1 of 4)
TURBINE INSTRUMENT SURVEY RESULTS
PART 1: Expansion and Position Data at Minimum and Full Load
Position
Location
Minimum
Load
Full Load
Control
Valve
No.
Position at
Minimum
load
Position at
Maximum
Load
Front standard expansion 1
Mid standard expansion 2
DXD- front standard 3
DXD- mid standard 4
Rotor expansion 5
Thrust A 6
Thrust B 7
CV servo 8
PART 2: System Oil Pressures
Location
Type Pressure Values Acceptable Unacceptable?
(State Reason)
Date Gage
Was Last
Calibrated
Main oil pump
discharge

MOP suction
Bearing header
Seal oil air/gas
Seal oil differential
At T-G
centerline
Stator cooling
water

MOP discharge
MOP suction
Bearing header
Seal oil/gas
Seal oil differential
At lube oil
tank or
skid
Stator cooling
water

A-37

TURBINE INSTRUMENT SURVEY RESULTS (CONTINUED)
PART 3: Water Induction Thermocouples
Unit
Load
Thermocouple
Description
Upper
TC
Value
Lower
TC
Value
Acceptability
Yes or No
Comments

PART 4: Start/Load Thermocouples
Unit
Load
Thermocouple
Description
Thermocouple
Value
Acceptable Comments

A-38
Data Sheet #11: (b) Turbine Instrumentation Survey Interview (Page 3 of 4)
TURBINE INSTRUMENTATION INTERVIEW
No. 1 Do the thermocouple readings make sense, and are they reporting temperatures at expected
values? Do any exhibit an unusual or excessive replacement rate?
No. 2 Are reported oil gage pressures consistent and within expected values? Do any exhibit calibration-
related problems?
No. 3 Are shaft vibration pick-ups providing consistent readings within expected values for each of the
bearings?
No. 4 Are the position and expansion meters reporting whether the rotor and casing expansion is smooth
during start-up and ramp-to-load, or is sudden movement reported?
No. 5 Are the pressures and temperatures that are monitoring for steam leakage providing consistent
readings within expected values?

A-39
Data Sheet #11: (c) Turbine Instrumentation Condition Assessment (Page 4 of 4)
ASSESSMENT OF CURRENT TURBINE INSTRUMENTATION CONDITION
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition Is
Allowed to
Continue As Is
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A-40
Data Sheet #12: (a) Generator-Exciter Inspection Audit (Page 1 of 3)
GENERATOR INSPECTION RESULTS
Component No. Type of Inspection or Check to Perform or
Review
Results Acceptable Not
Acceptable
1 Number of RTDs out of service
2 Full load RTD readings
3 Number of TCs out of service
4 Full load TC readings
5 End winding vibration readings versus
expected

6 Partial discharge data
7 Stator leak monitoring results
8 Latest megger or hipot results
9 Hydrogen leakage test results

Stator
10 Liquid level detector alarms or other oil ingress
issues

1 Full load amps and VARs comparison to
design curves

2 Dew point readings
3 Collector ring brush vibration
4 Hydrogen seal megger reading
5 Insulated bearing megger reading
6 Shaft voltage test results from PM routes

Field
7 Field megger readings
1 Commutator brush vibration
2 Commutator diameter DC Exciters
3 Commutator mica groove diameter
1 Collector brush vibration
2 Collector ring diameter
3 Bearing insulation megger reading
Alterrex
Exciters
4 RTD readings
1 Bearing insulation megger reading
2 No. of blown fuses
Brushless
Exciters
3 RTD readings

A-41
Data Sheet #12: (b) Generator-Exciter Inspection Interview (Page 2 of 3)
GENERATOR OPERATING INFORMATION INTERVIEW
No. 1 Have trends associated with dew point, hydrogen purity, vibration, or hydrogen consumption
remained stable and constant? For how long?
No. 2 Have any loadings occurred beyond the reactive capability curves, or have any unintentional loading
events occurred?
No. 3 Has there been any abnormal frequency operation?
No. 4 Have there been any operational mishaps, such as accidental overspeeds or synchronizing out of
phase?
No. 5 Have there been an excessive number of full load or part load trips? Due to what?
No. 6 Has any motoring of the generator occurred?

A-42
Data Sheet #12: (c) Generator-Exciter Condition Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT GENERATOR-EXCITER CONDITION
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition Is
Allowed to
Continue As Is
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A-43
Data Sheet #13: (a) Auxiliary System Operating Information Audit (Page 1 of 3)
AUXILLARY SYSTEM OPERATING INFORMATION SURVEY RESULTS
PART 1: Steam Seal System
Recorded Values Criteria:
(Values Noted May Vary with Each Unit)
Steam seal pressure 5 psi (34.5 kPa) typical
Vacuum (inches water) 3 to 5" water (0.71.2 kPa) typical
Any observed steam leakage at
glands?

Excessive leak-off from steam seal
header?

PART 2: Hydrogen Seal Oil System
Pressure Temp. Criteria:
Hydrogen cooler inlet gas
temperature
N/A

Hydrogen cooler gas exit temperature N/A
Vacuum at vacuum tank
1" Hg (3.4 kPa) minimum to maintain 97%
hydrogen purity. Can go as low as 26" Hg (88.0
kPa).
Temperature of vacuum pump
separator tank
Will be hot if excessive water in lube oil and
would need to be drained.
Hydrogen gas pressure and seal oil
pressure differential
N/A Varies with various units. Typical GE is 8 psi
(55.2 kPa) with alarm at 2.5 psi (17.2 kPa).
Delta P across main seal oil pump
filter
N/A

PART 3: Stator Cooling Water
System
Recorded Values Criteria:
Deionized water conductivity
(mhos/cm)

Alarm is at 0.5 mhos/cm.
P H
2
gas and stator cooling water
pressure
Should have positive P because water
pressure should be lower than hydrogen gas.
Cooling water inlet temperature
Should be 4045C (104113F), alarm is at
47C (116.6F).
Bulk water outlet temperature
Alarm at max capability is at 78C (172.4F);
runback is at 83C (181.4F).
Stator bar outlet temperatures for
each bar monitored

Alarm is at 83C (181.4F).
Stator bar temperatures Alarm is at 78C (172.4F).
Stator cooling water filter P 8 psi (55.2 kPa) is the maximum allowed.

A-44
Data Sheet #13: (b) Auxiliary System Information Interview (Page 2 of 3)
AUXILLARY SYSTEM OPERATING INFORMATION INTERVIEW
No. 1 Does the generator have liquid level alarm problems? Is the problem due to oil or water ingress into
the detectors? Does the unit have problems in maintaining hydrogen purity or hydrogen pressure?
No. 2 Does the unit have any problems with hydrogen leakage? If so, what is the daily hydrogen
consumption compared to its design leakage?
No. 3 What are the results of operational tests performed on the seal oil system? How frequently are they
performed? What are the results of preventive and predictive maintenance checks performed on
the seal oil system?

No. 4 Does the generator have high vibration problems during startup or shutdown, during high load or
low load?
No. 5 Has the stator cooling water system experienced any alarms due to (1) low flow, (2) low inlet
pressure, (3) high inlet temperature, (4) high stator bar temperature, or (5) conductivity? What has
been the frequency of each of these alarms? What was the root cause of these alarms?
No. 6 Has the unit experienced a low flow runback? If so, at what frequency? What has been identified as
the root cause?

No. 7 What operational tests are performed on the stator cooling water system? What were the results of
such tests? Has the failure of any operational test been resolved to your satisfaction?

No. 8 What equipment, instrumentation, and controls are included in your PM program? What is the
frequency of inspection and the results of these inspections? Are there any problems that have not
been resolved from the program? What do you believe the consequences can be from not having
resolved them?

No. 9 How frequently do you calibrate instruments and controls used for operation functions? Typically,
they are calibrated and tested at least annually.

No. 10 Who is responsible for determining the root cause of stator cooling system alarms or a low flow
runback? Have any occurred? What was the cause?

No. 11 What stator cooling water components are included in the PdM program?

No. 12 Are there any known problems that could result in alarm, runbacks, or serious harm to the stator
cooling water equipment?

A-45
Data Sheet #13: (c) Auxiliary System Condition Assessment (Page 3 of 3)
ASSESSMENT OF CURRENT AUXILLARY SYSTEM CONDITION
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence If
Condition
Allowed to
Continue As Is
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A-46
Data Sheet #14: (a) Visual Inspection Audit (Page 1 of 3)
VISUAL INSPECTION RESULTS
Area Visually inspected Major Finding or Observation
HP inlet at 1
st
stage

HP exhaust
IP inlet
IP exhaust
LPA inlet
LPA exhaust: (L-0, L-1)
LPB inlet
LPB exhaust: (L-0, L-1)
LPC inlet
T
U
R
B
I
N
E

LPC exhaust: (L-0, L-1)
Windings
Retaining rings
Through bolts
Blocking
Collector rings

G
E
N
E
R
A
T
O
R

Brushes

A-47
Data Sheet #14: (b) Visual Inspection Interview (Page 2 of 3)
VISUAL INSPECTION INTERVIEW
No. 1 When was the last time a visual inspection was made of the last stage turbine blades? Was any
noticeable erosion wear or damage found on any of the airfoils. What was the condition of the
shrouds, lugs, and tie wires?
No. 2 When was the last time the 1
st
HP or 1
st
reheat blades were visually inspected? Was there any
noticeable solid particle erosion or FOD? Was this apparent in the preceding inspection.
No. 3 When was the last time a visual inspection was performed on the generator components? What was
their apparent condition?

A-48
Data Sheet #14: (c) Visual Inspection Condition Assessment (Page 3 of 3)
VISUAL ASSESSMENT OF CURRENT CONDITION (BASED ON DATA AND INTERVIEWS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition
Allowed to
Continue As Is
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A-49
Data Sheet #15: (a) Checklist of Out-of-Limit Events and Conditions (Page 1 of 4)
AUDIT OF UNIT UPSETS OUT-OF-LIMIT CONDITION OCCURRENCES
Review the following with unit operators or other appropriate plant personnel.
Potential Impact on T-G
Reliability
No. Event Description How
Many
How
Long
Actions Taken. Does
Problem Still Persist?
No Yes H M L
1 Generator motored
2 Generator dew point
exceeded

3 Generator hydrogen
purity exceeded

4 Stator winding
vibration limit
exceeded

5 Out-of-phase
synchronization

6 Switching incidents
affecting generator

7 Insulation resistance
too low on bearing, H2
seal

8 Core monitor alarms
requiring operator
action

9 Stator coolant
conductivity exceeded

10 H2 consumption
exceeded maximum
allowable

11 Hydrogen in water-
cooled stator

12 Generator rotor
ground faults

13 Shaft voltage limit
exceeded

14 Stator ground faults
15 Liquid level alarms
and oil in stator

A-50
Reliability
Many
How
Long
Actions Taken. Does
No Yes H M L
16 Seal oil pressure low
17 Generator TC/RTD
limits exceeded

18 Negative sequence
alarms tripped

19 Failed seal oil pump
start tests

20 Failed stator cooling
pump start tests

21 Experienced
condenser tube leaks

22 Exceeded valve test
limits

23 Exceeded steam
purity limits

24 Exceeded air in
leakage limits

25 Experienced water
induction incidents

26 Exceeded maximum
back pressure for unit

27 Operated unit outside
of ramp rate and of
curves

28 Excessive partial- or
full-load trips

29 AC or DC pump start
failures

30 Exceeded lube oil/seal
oil EHC contamination
limits

31 Exceeded oil trip test
limits

32 Exceeded overspeed
trip test limits

33 Vibration too high at
speed or criticals

34 Numerous balance
shots needed since
last outage

35 Main steam inlet
temperature
excursions

A-51
Reliability
Many
How
Long
Actions Taken. Does
No Yes H M L
36 Reheat steam inlet
temperature
excursions

37 HI-IP differential
temperature exceeded

38 Crossover temperature
excursions

39 HP or IP inlet pressure
exceeds maximum
allowable

40 DXD or RXD
expansion limits
exceeded

41 Thrust wear limit
exceeded

42 Temperature excursion
on thrust/journal
bearing

43 Turning gear start/stop
problems

44 High diff pressure
across seal oil /lube
oil/EHC filters

45 Steam seals blow
during operation

46 Water in lube oil/seal
oil/EHC

47 LP hood sprays do not
operate properly

48 PM or PdM not
performed as expected
on unit

49 Start/load, water
induction
thermocouples fail

50 Excess run out: HP
control rotor or
extension shaft

51 Low lube oil pressure
at centerline

52 High P across stop or
intercept valves

53 Low MOP suction or
discharge pressure

54 EHC pump start test
failure

A-52
Data Sheet #15: (a) Checklist of Out-of-Limit Events-Conditions (Page 4 of 4)
Reliability
Many
How
Long
Actions Taken. Does
No Yes H M L
55 Low lube oil pressure
56 Low control or impeller
oil pressure

57 Sudden change in HP
performance

58 Sudden change in IP
performance

59 Sudden change in LP
performance

60 Unit erratic on load
control

61 Valves stick or tend to
hang up

62 Station batteries need
PM or have other
issues

63 MHC or EHC control
problems or issues

64 Vibration problems at
low load or during
startup

65 Front standard is sticky
or hangs up

66 Mid-standard is sticky
or tends to hang up

67 Steam leaks around
shells or HP flanges

68 Have any turbine
shells been pumped to
stop steam leaks?

69 Are the turbine CV
crack and intercept
points out of OEM
spec.?

A-53
Data Sheet #15: (b) Condition Assessment for Out-of-Limit Events (Page 1 of 1)
ASSESSMENT OF CURRENT T-G CONDITION (BASED ON OUT-OF-LIMIT EVENTS)
Risk of Failure
Need for
Action
Potential
Issues or
Problems
with Present
Condition
Consequence
If Condition Is
Allowed to
Continue As Is
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A-54
Data Sheet #16 (a): Current Long-Range Maintenance Plan for Unit (Page 1 of 3)
Plant and Unit Number: PAGE 1
CURRENT LONG-RANGE MAINTENANCE PLANS FOR UNIT
Component or System Date of
Last
Inspection
Year of
Next
Inspection
Inspection
Frequency in
Years
Comments as to Risks
Based on Condition
Assessment
HP turbine
IP turbine
LPA turbine
LPB turbine
T
U
R
B
I
N
E
S

LPC turbine
Crawl through
Field removal
Voltage regulator
calibration

Hydrogen coolers
G
E
N
E
R
A
T
O
R
-
E
X
C
I
T
E
R

Field removed
Speed load changer
Governor
Aux governor
Trip anticipator
Primary speed relay
Secondary speed relay
TV controller
CV operator cylinder
SV/TV operator cylinder
IV operator cylinder
RSV operator cylinder
C
O
N
T
R
O
L

S
Y
S
T
E
M

Other control components
(list)

Aux oil pump/motor
TG oil pump/motor
DC oil pump/motor
Ejector/booster pump
Oil tank and bowser
Lift pumps
L
U
B
E

O
I
L

S
Y
S
T
E
M

Oil coolers

A-55
Data Sheet #16 (b): Current Long-Range Maintenance Plan for Unit (Page 2 of 3)
Last
Inspection
Year of
Next
Inspection
Inspection
Frequency in
Years
Based on Condition
Assessment
Control or governor
valves

Intercept valves
Stop or throttle valves
Reheat stop valves
Ventilator valve
Blow down valve
Equalizer valve
V
A
L
V
E
S

Extraction non-return
valves

Main seal oil pump
(air/gas)

Recirculation seal oil
pump

Vacuum pump
DC backup pump
Detraining tanks and float
trap

P
U
M
P
S

Coolers and filters
Main seal oil pump
(air/gas)

Recirculation seal oil
pump

Vacuum pump
DC backup pump
Detraining tanks and float
trap

S
E
A
L

O
I
L

S
Y
S
T
E
M

Coolers and filters
Diverter valve
Regulator
Strainers
S
T
E
A
M

S
E
A
L

Exhauster fan and motors
Pumps and motors
Coolers and
filters/strainers

Change deionizing resin
S
T
A
T
O
R

C
O
O
L
I
N
G

Regulators and flow
meter

A-56
Data Sheet #16 (c): Current Long-Range Maintenance Plan for Unit (Page 3 of 3)
Last
Inspection
Year of
Next
Inspection
Inspection
Frequency in
Years
Based on Condition
Assessment
Individual turbine sections
Tops ontops off
alignment

A
L
I
G
N
M
E
N
T

Turbine rotor boresonics
Generator rotor
boresonics

Retaining ring ultrasonic
M
A
J
O
R

N
D
E

Turbine wheel dovetail
UT/NDE

Major unit oil flush
Valve controls lineup
Turning gear and motor
Exhaust hood spray
nozzles

M
I
S
C
E
L
L
A
N
E
O
U
S

Pre-warming system
valves

O
T
H
E
R

A
C
T
I
V
I
T
I
E
S

(
L
I
S
T
)

A-57
Data Sheet #17: (a) Overall Unit Condition Assessment Form
Plant and Unit Number
CONDITION ASSESSMENT SUMMARY
DEGRADATION Component or
System
Severe Significant Some
GOOD
CONDITION
Comments

Recommendations:

B-1
B
TURBINE-GENERATOR OUTAGE REPORT
B.1 Outage Report Instructions
The basic principle behind this format is the flexibility to write the report as the outage
progresses. If someone spends approximately one hour a day updating the report, at the end of
the job the outage report is basically complete except for minor clerical details.
I. Introduction
Under introduction make sure to include off line date and time, turning gear date and time
and return to service date and time. Use military hours (24-hour clock).
List bulletins if used. If not, just say no bulletins were implemented during this outage.
II. Name Plate Rating
III. Outage Personnel
Use only the lines you need. Correct A, B. C., etc. If you do not have an NDE person, you
omit and go to the next one.
IV. Summary of Recommendations
Should be worded the same as in recommendations in the report. If you say normal
inspection next outage or none, you dont have to list. It is a good idea just to leave a full
page and then when you complete the report, go back, copy, cut, paste and put your
recommendations in from your recommendations in the report. Just remember if you cut and
paste, include the component you are talking about in this section.
V. Work Summary
The turbine and generator are broken down into components. Each component is then broken
down into the following sections (This does not include any data sheets. This is verbage):
1. Work scope This includes what the original workscope was for that component. This
can be written up before the outage actually starts.
2. Inspection The as found condition of the component.

Turbine-Generator Outage Report
B-2
3. Maintenance What repairs were, if any, to the component. This may include more work
than the original work scope called for.
4. Reassembly The as left condition of the component.
5. Recommendations - Any recommendations for the next time this component is inspected.
This section should also be copied to the Summary of Recommendations section.
Make sure you input information in each section as work is being performed each day. This
will make sure certain that information is not lost when the outage gets very busy. Go to the
section you need and begin keying. What you dont need, highlight and delete.
VI. Data Sheets
Make certain you put the exact title as it appears on the data sheet. Show As Found - As
Assembled, R/S L/S - Coupling #.
Make certain all date sheets are signed and dated. If you have your data sheets keyed and the
names typed in, they still have to be signed.
VII. Test Data
All test data including NDE.
VIII. Photos
IX. Appendix
You will always have a Replacement Parts Used List. You may have a Turbine Assessment
Report, etc. Whatever does not qualify for the Contractors, Report section goes under
Appendix.
X. Contractors Reports
List each contractor such as (so that their report will not be overlooked):
A. WSI Inc.
B. Welding Services Inc.
If you do not have contractors, make a sheet showing none.
If you have an OEM representative, make certain that he signs all data sheets.

B-3
B.2 Report Table of Contents
_________ (Plant - Unit)
__________Inspection (HP, IP, LP, Gen, Vlvs, etc)
_________(Outage)
__________(Dates of Outage)
Page No.
I. Introduction __
II. Name Plate Ratings __
III. Outage Personnel __
A. Outage Engineer
B. Maintenance Supervisors
C. Foremen
D. Turbine Assessment Group
E. NDE Personnel
IV. Summary of Recommendations __
V. Work Summary __
A. HP Turbine __
1. Outer Cylinder __
2. Inner Cylinder/Blade Rings __
3. Nozzle Block __
4. Stationary Blading __
5. Rotating Blading __
6. Glands and Gland System __
7. Rotor and Extension Shaft __
8. Bearings, Pedestals and Thrust Bearing __
9. Crossover/Crossunder Piping __
10. Main Oil Pump __
11. Auxiliaries (AC & DC Pumps, Lube Oil Coolers, etc.) __
12. HP Other __
B. IP Turbine __

B-4
7. Bearing, Pedestals and Thrust Bearings __
8. Crossover/Crossunder Piping __
9. IP Other __
C. LP Turbine __
7. Bearing, Pedestals and Thrust Bearings __
8. Crossovser/Crossunder Piping __
9. Turning Gear __
10. LP Other __
D. Generator __
1. Collector Rings and Brush Rigging __
2. Bearing Brackets __
3. Outer Casing or Frame __
4. Hydrogen Coolers __
5. Hydrogen Seals and Bracket __
6. Hydrogen Cooling System __
7. Air Cooling System __
8. Seal Oil System __
9. Air Gap Baffling Cooling System __
10. Generator Rotor - Mechanical __
11. Generator Rotor - Electrical __
12. Generator Stator - Electrical __
E. Exciter __
1. Exciter - Mechanical __
2. Exciter - Electrical __
3. Commutator and Brushes __
F. Valves __
1. Throttle Valves __
2. Governor Valves __

B-5
3. Intercept Valves __
4. Reheat Valves __
G. Other __
1. BFPT __
2. Extraction System & Piping __
3. Oil Flush __
4. Governing System/Hydraulic System __
5. Voltage Regulator __
6. Miscellaneous Turbine - Generator __
VI. Data Sheets __
VII. Test Data __
VIII. Photos __
IX. Appendix __
X. Contractors Reports __

B-6
B.3 Blank Report Format
_________(Plant - Unit)
__________Inspection (HP, IP, LP, Gen, Vlvs, etc.)
_________(Outage
__________(Dates of Outage)
I. Introduction
The unit was removed from service April 2, 1998, at 2340 hours for a scheduled/unscheduled
outage. The work scope consisted of inspection of__________________________________
__________________________________________________________________________
The unit went on turning gear (date) at hours. The unit was returned to
service (date) at hours. (Use military hours.)
The following engineering bulletins were implemented during this outage.

Start-Up

B-7
II. Name Plate Rating

III. Outage Personnel
A. Outage Engineer
B. Maintenance Supervisors
C. Foremen
D. Turbine Assessment Group
E. NDE Personnel

B-8
IV. Summary of Recommendations

(Should be the same as in the report under recommendations for each component.)

B-9
V. Work Summary
A. HP Turbine
1. Outer Cylinder
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
2. Inner Cylinder/Blade Rings
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
3. Nozzle Block
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
4. Stationary Blading
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
5. Rotating Blading
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-10
V. A. HP Turbine - continued
6. Glands and Gland System
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
7. Rotor and Extension Shaft
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
8. Bearings, Pedestals, and Thrust Bearing
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
9. Crossover/Crossunder Piping
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
10. Main Oil Pump
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-11
V. A. HP Turbine - continued
11. Auxiliaries (AC & DC Pumps, Lube Oil Coolers, etc.)
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
12. HP Other
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
B. IP Turbine
1. Outer Cylinder
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-12
V. B. IP Turbine - continued
4. Rotating Blading
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
7. Bearing, Pedestals, and Thrust Bearings
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-13
V. B. IP Turbine - continued
9. IP Other
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
C. LP Turbine
1. Outer Cylinder
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
4. Rotating Blading
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-14
C. LP Turbine (continued)
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
7. Bearing, Pedestals, and Thrust Bearings
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
9. Turning Gear
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-15
C. LP Turbine (continued)
10. LP Other
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
D. Generator
1. Collector Rings and Brush Rigging
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
2. Bearing Brackets
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
3. Outer Casing or Frame
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
4. Hydrogen Coolers
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-16
D. Generator (continued)
5. Hydrogen Seals and Bracket
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
6. Hydrogen Cooling System
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
7. Air Cooling System
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
8. Seal Oil System
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
9. Air Gap Baffling Cooling System
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-17
D. Generator (continued)
10. Generator Rotor - Mechanical
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
11. Generator Rotor - Electrical
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
12. Generator Stator - Electrical
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
E. Exciter
1. Exciter - Mechanical
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
2. Exciter - Electrical
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-18
E. Exciter (continued)
3. Commutator and Brushes
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
F. Valves
1. Throttle Valves
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
2. Governor Valves
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
3. Intercept Valves
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
4. Reheat Valves
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-19
G. Other
1. FWPT
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
2. Extraction System & Piping
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
3. Oil Flush
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
4. Governing System/Hydraulic System
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations
5. Voltage Regulator
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-20
G. Other (continued)
6. Miscellaneous Turbine - Generator
a. Work Scope
b. Inspection
c. Maintenance
d. Reassembly
e. Recommendations

B-21
VI. Data Sheets
Prepare an index for each data sheet, whether 1 or 300. Be sure to show as found, as left,
etc., where applicable. All data sheets must be signed by the person taking the readings:
foreman, maintenance supervisor, OEM representative, or outage engineer.
See Appendix C for the data sheets.

B-22
VII. Test Data
Test data are to be placed here.

B-23
VIII. Photos
Place photos two to a page indicating what the picture depicts - as found, as left, etc. Pasted,
not taped.

B-24
IX. Appendix
Replacement Turbine Parts Used List.
(Turbine Assessment Reports, etc.)
Any other information or reports that do not apply to Contractors Reports, for example,
Turbine Assessment Reports.

B-25
X. Contractors Reports

C-1
C
DATA SHEETS
These forms are grouped into major categories as follows:
I. Turbine Axial/Radial Clearances, Alignment, and Radial/Axial Position
Sheet #1: N Wheel Clearance Record.............................................................................. C-7
Sheet #2: Wheel Clearance Record with Twist and Variation ............................................. C-8
Sheet #3: Turbine Generator Alignment Record Tops Off ............................................... C-9
Sheet #4: Turbine Generator Alignment Record Tops On ............................................. C-10
Sheet #5: Bolted Diaphragm Drop, Level, and Side Slip Check........................................ C-11
Sheet #6: Barn Door Latch Diaphragm Axial Crush Pin Clearances............................ C-12
Sheet #7A: Spill Strip and Diaphragm Packing Clearance Data ....................................... C-13
Sheet #7B: Spill Strip and Diaphragm Packing Clearance Data ....................................... C-14
Sheet #8: Rotor Axial Position.......................................................................................... C-15
Sheet #9: HP Rotor Axial Position.................................................................................... C-16
Sheet #10: Steam Packing Butt Clearances..................................................................... C-17
Sheet #11: Steam Packing Wear Measurements ............................................................. C-18
Sheet #12A: Diaphragm Clearance Record...................................................................... C-19
Sheet #12B: Diaphragm Clearance Record...................................................................... C-20
Sheet #12C: Diaphragm Clearance Record with Z and W Clearances ............................. C-21
Sheet #13: Interstage Packing Clearance Wear Measurements....................................... C-22
Sheet #14: Shell Arm Elevation Keys as Miked ................................................................ C-23
Sheet #15: LP Steam Gland............................................................................................. C-24
Sheet #16: Rotor and Water Gland Dimensions ............................................................... C-25
Sheet #17: Water Gland Clearances ................................................................................ C-26
Sheet #18: LSB Radial Tip Clearances ............................................................................ C-27
Sheet #19: Axial/Radial Clearances Curtis Blades ........................................................ C-28
Sheet #20: Reaction Blade Clearances............................................................................ C-29
Sheet #21: Turbine Dummy Seal Clearances................................................................... C-30
Sheet #22: Packing Gland Dimensions (Sample) ............................................................. C-31
Sheet #23: Inboard Pedestal Base Plate Gibb Key Clearances........................................ C-32

Data Sheets
C-2
Sheet #24: Coupling Half to Pedestal Axial Position...................................................... C-33
Sheet #25: Assembled Coupling Axial Position ............................................................. C-34
Sheet #26: Bearing Ring to Housing Check...................................................................... C-35
Sheet #27: Turning Gear (Sample)................................................................................... C-36

II. Turbine Bearings, Journals, Oil Seals/Deflectors, Seal Rings, and Coupling
Data
Sheet #28: Journal Bearing Clearance and Pinch ............................................................ C-37
Sheet #29: Bearing Tilt/Twist Checks............................................................................... C-38
Sheet #30: Bearing Load Test .......................................................................................... C-39
Sheet #31: Bearing Fillet Clearances ............................................................................... C-40
Sheet #32: Journal Dimensions........................................................................................ C-41
Sheet #33: Bearing Orifice Inspection Checks.................................................................. C-42
Sheet #34: Thrust Bearing (Overhung)............................................................................. C-43
Sheet #35: Thrust Bearing (Straddle) ............................................................................... C-44
Sheet #36: Thrust Bearing (Independently Mounted-Tapered Land/CCW) Checks .......... C-45
Sheet #37: Thrust Bearing (Independently Mounted-Tapered Land/CW) Checks............. C-46
Sheet #38: Thrust Assembly (Sample) ............................................................................. C-47
Sheet #39: Thrust Bearing Thermocouple Measurements................................................ C-48
Sheet #40: Tilt Pad Bearing Oil Seal Ring and Shaft Dimensions..................................... C-49
Sheet #41: Thrust Cage Oil Seal Rings............................................................................ C-50
Sheet #42: Bull Gear to Coupling Rabbet Fit Check ......................................................... C-51
Sheet #43: Coupling Eccentricity Runout.......................................................................... C-52
Sheet #44: Rotor Radial Runout Checks .......................................................................... C-53
Sheet #45: Coupling Inspection Checks ........................................................................... C-54
Sheet #46A: Coupling Alignment Data Sheet ................................................................... C-55
Sheet #46B: Rotor Coupling Alignment Check Summary ................................................. C-56
Sheet #47: Rotor Radial Position Tight Wire vs. Shaft ................................................... C-57
Sheet #48: Oil Bore Radial Position.................................................................................. C-58
Sheet #49: Gland Bore Radial Position ............................................................................ C-59
Sheet #50: Rotor (Axial) Position Data ............................................................................. C-60
Sheet #51: Rabbet Fit of the No. 1 Coupling (Sample) ..................................................... C-61
Sheet #52: Rabbet Fit of the No. 2 Coupling (Sample) ..................................................... C-62
Sheet #53: Coupling Bolt Assembly Data......................................................................... C-63
Sheet #54: Oil Deflector Check ........................................................................................ C-64

Data Sheets
C-3
Sheet #55: Oil Rings ........................................................................................................ C-65
Sheet #56: Rotor Oil Seal/Deflector Clearances (Sample)................................................ C-66

III. Cylinders, Shells, Rotors, and Blade Ring Dimensional Data
Sheet #57: Cylinder Support Block and Liner Clearances................................................. C-67
Sheet #58: IP Turbine Inner Cylinder Bore Diameters ...................................................... C-68
Sheet #59: Bolt Stretch Chart ........................................................................................... C-69
Sheet #60: HP Cylinder Flange/Steam Line Flange.......................................................... C-70
Sheet #61: HP Inlet Steam Flange Bolt Stretch (Sample)................................................. C-71
Sheet #62: IP Turbine and Inner Cylinder Sleeve/Bore Diameter (Sample) ...................... C-72
Sheet #63: LP Inner Cylinder Bolting and Half Joint Layout (Sample) .............................. C-73
Sheet #64: Nozzle Inlet Ring Clearances ......................................................................... C-74
Sheet #65: HP Turbine Elevation Block Clearance (Sample)............................................ C-75
Sheet #66: IP Rotor Dimensions (Sample) ....................................................................... C-76
Sheet #67: HP Cylinder Feeler Gauge Readings (Sample) .............................................. C-77
Sheet #68: IP Rotor Runout (Sample) .............................................................................. C-78
Sheet #69: IP Cylinder No. 1 Blade Ring Dimensions (Sample) ....................................... C-79
Sheet #70A: IP Blade Ring Dimensions (Sample) ............................................................ C-80
Sheet #70B: IP Blade Ring Dimensions (Sample) cont.................................................. C-81
Sheet #71: IP Rotor Dimensions (Sample) ....................................................................... C-82

IV. Controls and Front Standard Mechanisms
Sheet #72: Main Operating Cylinder ................................................................................. C-83
Sheet #73: Pilot Valve Assembly...................................................................................... C-84
Sheet #74: Governor Drive............................................................................................... C-85
Sheet #75: Speed Relay................................................................................................... C-86
Sheet #76: Pilot Valve and Bushing.................................................................................. C-87
Sheet #77: Pilot Valve Assembly...................................................................................... C-88
Sheet #78: Thrust Bearing Wear Detector ........................................................................ C-89
Sheet #79: Throttle Valve Servomotor.............................................................................. C-90
Sheet #80: Intercept Valve Servo Relays ......................................................................... C-91
Sheet #81: Intercept Valve Servo..................................................................................... C-92
Sheet #82: Intercept Valve Servo and Test Piston............................................................ C-93
Sheet #83: Intercept Valve Servo Pilot Piston and Guide ................................................. C-94
Sheet #84: Reheat Valve Servo and Pilot Pistons ............................................................ C-95

Data Sheets
C-4
Sheet #85: Reheat Valve Servo Dump and Operating Pistons ......................................... C-96
Sheet #86: Auto Stop Trip Assembly (Sample).............................................................. C-97
Sheet #87: Load Limit (Low Load) .................................................................................... C-98
Sheet #88: Load Limit (High Load) ................................................................................... C-99
Sheet #89: Auxiliary Governor........................................................................................ C-100
Sheet #90: Main Governor ............................................................................................. C-101
Sheet #91: Governing Valve Servomotor........................................................................ C-102
Sheet #92: Backup Pilot Valve Relay Assembly ............................................................. C-103
Sheet #93: Quill Shaft Inspection Form.......................................................................... C-104

V. Oil Pumps
Sheet #94: Main Oil Pump Simple Suction................................................................... C-105
Sheet #95: Main Oil Pump-Double Suction..................................................................... C-106
Sheet #96: Turbine Shaft Main Oil Pump........................................................................ C-107
Sheet #97: Auxilary Pump-Turbine Driven...................................................................... C-108
Sheet #98: Oil Pump-Motor Driven................................................................................. C-109
Sheet #99: Oil Pump-Motor Driven................................................................................. C-110

VI. Main Turbine Valves
Sheet #100: Control Valve Stems and Bushings............................................................. C-111
Sheet #101: Control Valve Crossheads and Discs ......................................................... C-112
Sheet #102: Steam Chest Plug Dimensions................................................................... C-113
Sheet #103: Governor Valve Lift Rods and Bushings..................................................... C-114
Sheet #104: Governor Valve Seat Elevation................................................................... C-115
Sheet #105: Steam Chest Governor Valve Settings ....................................................... C-116
Sheet #106: Main Stop Valve ......................................................................................... C-117
Sheet #107: Main Stop Valve Full Arc Bypass Controlled............................................ C-118
Sheet #108: Main Stop Valve Bypass Type................................................................. C-119
Sheet #109: Throttle Valve/Intercept Valve Clearance (Sample) .................................... C-120
Sheet #110: Throttle Valve Clearance Data (Sample) .................................................... C-121
Sheet #111: Throttle Valve Squareness Check .............................................................. C-122
Sheet #112: Intercept Valve Clearance Data.................................................................. C-123
Sheet #113: Combined Reheat Stop-Intercept Valve...................................................... C-124
Sheet #114: Intercept Valve Separately Mounted........................................................ C-125
Sheet #115: Intercept Valve Shell Mounted................................................................. C-126

Data Sheets
C-5
Sheet #116: Reheat Stop Valve Separately Mounted.................................................. C-127
Sheet #117: Reheat Stop Valve and Servomotor ........................................................... C-128
Sheet #118: Ventilator Valve .......................................................................................... C-129
Sheet #119: Emergency Blowdown Valve ...................................................................... C-130
Sheet #120: Valve Gasket Check................................................................................... C-131
Sheet #121: Screen and Valve Dimensions.................................................................... C-132
Sheet #122: Valve Couplings ......................................................................................... C-133
Sheet #123: Cam Rods .................................................................................................. C-134
Sheet #124: Control Valve Settings (Sample)................................................................. C-135
Sheet #125: Valve Gasket Compression........................................................................ C-136
Sheet #126: Stem Seal Regulator .................................................................................. C-137

VII. Generator-Exciter
Sheet #127: Generator Information Sheet 1................................................................. C-138
Sheet #128: Generator Information Sheet 2 ................................................................ C-139
Sheet #129: Hydrogen Seal Oil System Inspection ........................................................ C-140
Sheet #130: Hydrogen Seal Inspection .......................................................................... C-141
Sheet #131: Generator Hydrogen Seal Clearances........................................................ C-142
Sheet #132: Generator Seal Settings ............................................................................. C-143
Sheet #133: Generator Journal Diameters ..................................................................... C-144
Sheet #134: Generator Journal Diameters ..................................................................... C-145
Sheet #135: Hydrogen Gas System Inspection .............................................................. C-146
Sheet #136: Stator Cooling System Inspection............................................................... C-147
Sheet #137: Generator Air Gap Baffle Clearances ......................................................... C-148
Sheet #138: Generator Fan Clearances ......................................................................... C-149
Sheet #139: Blower Blade Clearances ........................................................................... C-150
Sheet #140: Exciter Armature Inspection Form.............................................................. C-151
Sheet #141: Exciter Reduction Gear Bearing and Shaft Dimensions.............................. C-152
Sheet #142: Exciter Bearing Inspection Form................................................................. C-153
Sheet #143: Exciter Pinion Gear Inspection Form.......................................................... C-154
Sheet #144: Exciter Bull Gear Inspection Form.............................................................. C-155
Sheet #145: Exciter Oil Seal Inspection Form ................................................................ C-156
Sheet #146: Exciter DC Motor/Generator Gap Inspection .............................................. C-157
Sheet #147: Exciter DC Drop Test Inspection Form....................................................... C-158
Sheet #148: Exciter Seal to Journal Setting.................................................................... C-159

Data Sheets
C-6
Sheet #149: Generator/Exciter Rotor Seal and Collector Area ....................................... C-160
Sheet #150: Exciter Coupling Alignment Form............................................................... C-161

VIII. Protective Device and Pre-Operational Checks
Sheet #151: Protective Device and Pre-Operational Checks Sheet 1.......................... C-162

IX. Vibration and Balance
Sheet #154: Vibration Data Sheets................................................................................. C-165
Sheet #155: Balance Weight Locations .......................................................................... C-166

Data Sheets
C-7
Sheet #1: N Wheel Clearance Record
Plant ________________________ Readings Taken By ________________________ Date _____________
Unit ________________________ Reviewed by Foreman______________________ Date _____________
Outage No.______________________ Outage Supervisor_________________________ Date _____________
As Found ________________ Reviewed by O.E.M. ________________________ Date _____________
As Assembled____________ Outage Engineer __________________________ Date _____________
Date __________________ Turbine Serial No._________________________ Prepared by _______________
Left Side of Turbine Recheck Right Left Side of Turbine Recheck Right Sta.
No
1L 2 3 4 1L 1R
Sta.
No.
1L 2 3 4 1L 1R
A A
E E
D D
A A
E E
D D
A A
E E
D D
A A
E E
D D
A A
E E
D D
A A
E E
D D
A A
E E
D D
A A
E E
D D
A A
E E
D D
A A
E E
D D
A = Actual, E = Expected, D = Difference

Data Sheets
C-8
Sheet #2: Wheel Clearance Record with Twist and Variation
Clearance on Left Side of Turbine Right Max Twist
S
t
a
.

C
l
e
a
r

1L 2 3 4 5 6 7 8 Check
1L
1R
E
x
p
.

V
a
r
i
a
t
i
o
n

M
a
x
.

V
a
r
i
a
t
i
o
n

E
x
p
.

T
w
i
s
t

- +
E

N
A
E

R
A
E

S
A
E

N
A
E

J
A
E

N
A
E

J
A
E

N
A
E

J
A
E

N
A
E

J
A
E

N
A
E

J
A
E

N
A
E

J
A
E = Expected, A = Actual

Data Sheets
C-9
Sheet #3: Turbine Generator Alignment Record Tops Off

Data Sheets
C-10
Sheet #4: Turbine Generator Alignment Record Tops On

Data Sheets
C-11
Sheet #5: Bolted Diaphragm Drop, Level, and Side Slip Check

Actual Drop Lower Half Levelness Side Slip Stage
Left
Mils
Right
Mils
Diameter
Inch
Level
Mils/Inch
Tol Actual Tol

Data Sheets
C-12
Sheet #6: Barn Door Latch Diaphragm Axial Crush Pin Clearances

Turbine Crush Pin Location
Stage Bottom Top
1 2 3 4 5 6 7 8 9 10
Slot(S)
Diap(D)
Clearance

Slot(S)
Diap(D)
Clearance

Slot(S)
Diap(D)
Clearance

Slot(S)
Diap(D)
Clearance

Slot(S)
Diap(D)
Clearance

Slot(S)
Diap(D)
Clearance

Slot(S)
Diap(D)
Clearance

Data Sheets
C-13
Sheet #7A: Spill Strip and Diaphragm Packing Clearance Data

Note: See Sheet 7B.

Data Sheets
C-14
Sheet #7B: Spill Strip and Diaphragm Packing Clearance Data
Sta.
No
Radial Clearances Axial Clearances
M Z-1L Z-1R Z-2 L Z-2 R W L W R R L R R X Y Z-3 Z-4 XA FIG(s)
A
E
D
A
E
D
A
E
D
A
E
D
A
E
D
A
E
D
A
E
D
A
E
D
A
E
D
A
E
D

Data Sheets
C-15
Sheet #8: Rotor Axial Position
Thrusted to Governor Thrusted to Generator Location
Left Right Left Right

Comments

Data Sheets
C-16
Sheet #9: HP Rotor Axial Position

Comments

Data Sheets
C-17
Sheet #10: Steam Packing Butt Clearances
Top Bottom Clearances Machined Sta. No. Ring No.
Left Right Left Right Left Right Left Right

Comments

Data Sheets
C-18
Sheet #11: Steam Packing Wear Measurements
Radial Packing Ring Height (Ht) Sta.
No.
Ring.
No.
X Y
Left Right 1 2 3 4 5 6 7 8

Data Sheets
C-19
Sheet #12A: Diaphragm Clearance Record
TB Section ___________________________

Note: See Sheets 12B and 12C.

Data Sheets
C-20
Sheet #12B: Diaphragm Clearance Record
TB Section ___________________________
Wheel Discharge Side Clearances Wheel Admission Side Clearances Sta.
No
P A B C D E G H I J K L L'L L'R V
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D

Data Sheets
C-21
Sheet #12C: Diaphragm Clearance Record with Z and W Clearances
Sta. XA P A D ZL ZR WL WR V H K L'L L'R L M
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D
E
A
D

Data Sheets
C-22
Sheet #13: Interstage Packing Clearance Wear Measurements
Radial Packing Ring Height (Ht) Sta.
No.
Ring
No.
X Y
Left Right 1 2 3 4 5 6 7 8

Data Sheets
C-23
Sheet #14: Shell Arm Elevation Keys as Miked

High Pressure

L.S. Gov. End R.S. Gov. End
1 1
2 2
3 3
4 4
5 5
6 6
SHIM SHIM

1 1
2 2
3 3
4 4
5 5
6 6
SHIM SHIM

Intermediate
Pressure

1 1
2 2
3 3
4 4
5 5
6 6
SHIM SHIM

Data Sheets
C-24
Sheet #15: LP Steam Gland

Left Side Right Side
ROW A B X Y A B X Y
1 Gov End
Outer Gland
2
3
4
5

Gov End
Inner Gland
6
7
8
9

Gen End
Inner Gland
10
11 Gen End
Outer Gland
12
Note: Packing is to be wedged in direction of steam flow.

Data Sheets
C-25
Sheet #16: Rotor and Water Gland Dimensions

Gland No. A B C D E

Data Sheets
C-26
Sheet #17: Water Gland Clearances

No. AL AR BL BR CL CR DL DR EL ER FL FR GL GR HL HR

Data Sheets
C-27
Sheet #18: LSB Radial Tip Clearances

Radial Clearance
Blade No. Gov. End Blade No. Gen. End
Top
Bottom
R.S. Above Joint
R.S. Below Joint
L.S. Above Joint
L.S. Below Joint

Data Sheets
C-28
Sheet #19: Axial/Radial Clearances Curtis Blades

Radial Axial
DIM Gen.
L
Gen.
R
Gov.
L
Gov.
R
DIM Gen.
L
Gen.
R
DIM Gen.
L
Gov.
R
A I Q
B J R
C K S
D M T
E N U
F O V
G P W
H

Data Sheets
C-29
Sheet #20: Reaction Blade Clearances

Section ________

Spindle Set with K
Dimension of _______
Spindle End Mic. _______
ROW AL AR BL BR EL ER FL FR LL LR ML MR SL SR TL TR

Data Sheets
C-30
Sheet #21: Turbine Dummy Seal Clearances

Actuals Left Side Actuals Right Side Expected
Position Ring
No.
Gov.
X
Gen.
Y
Radial* Gov.
X
Gen.
Y
Radial* Gov.
X
Gen.
Y
Radial*

Data Sheets
C-31
Sheet #22: Packing Gland Dimensions (Sample)

Packing/Gland
Location
Row A B C D E F Avg. Shaft
Diameter
Clear.
#1 Outer 1
#2 Outer 2
#1 Inner 1
#1 Inner 2
#1 Inner 3
#1 Inner 4
#1 Inner 5
#1 Inner 6
#1 Inner 7
HP Dummy 1
HP Dummy 2
HP Dummy 3
HP Dummy 4
HP Dummy 5
HP Dummy 6
HP Dummy 7
HP Dummy 8
LP Dummy 9
LP Dummy 10
LP Dummy 11
LP Dummy 12
LP Dummy 13
#2 Inner 8
#2 Inner 9
#2 Inner 10
#2 Inner 11
#2 Inner 12
#2 Inner 13
#2 Outer 1
#2 Outer 2
#3 Outer 1
#3 Outer 2
#3 Inner 1
#3 Inner 2
#3 Inner 3
#3 Inner 4
#4 Inner 1
#4 Outer 1
#4 Outer 2
#5 Outer 1
#5 Outer 2
#5 Inner 1
#6 Inner 1
#6 Outer 1
#6 Outer 2

Data Sheets
C-32
Sheet #23: Inboard Pedestal Base Plate Gibb Key Clearances

Data Sheets
C-33
Sheet #24: Coupling Half to Pedestal Axial Position

Data Sheets
C-34
Sheet #25: Assembled Coupling Axial Position

Data Sheets
C-35
Sheet #26: Bearing Ring to Housing Check

Data Sheets
C-36
Sheet #27: Turning Gear (Sample)

Comments

Data Sheets
C-37
Sheet #28: Journal Bearing Clearance and Pinch

Inspections & Checks Code
Ball Contact Check ______
Ball Pinch Check ______
Ball Torque Check ______
Twist & Tilt Check ______
Bearing Inspection ______
Journal Inspection ______
Babbit Inspection ______
Screen & Orifices ____
Thermocouples Calib. ___
____
____
____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Forward or Turbine End Aft or Generation End Bearing
Number
Bearing
Type
A-Dia. B-Dia. C-Dia. A-Dia. B-Dia. C-Dia.
Journal
Diameter
Shim
Thickness
Lead Wire
Size

Data Sheets
C-38
Sheet #29: Bearing Tilt/Twist Checks

Tilt = OV IV OT + IT
Bearing
Number
OV IV OT IT Limits
.0000 TO
Actual Bearing
Number
OV IV OT IT Limits
.0000 TO
Actual
1 7
2 8
3 9
4 10
5 11
6 12
Twist (Initial) = (OL IL + IR OR)/2 Twist (Recheck)
Bearing
Number
OL IL IR OR Limits
+ or -
Actual Bearing
Number
OL IL IR OR Limits
+ or -
Actual
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12

Data Sheets
C-39
Sheet #30: Bearing Load Test

Indicator
Reading
Weight
(lbs)
+0.000
+0.005
+0.010
+0.010
+0.005
+0.000
-0.005
-0.010
-0.010
-0.005
+0.000

Data Sheets
C-40
Sheet #31: Bearing Fillet Clearances

Bearing Number A B C D
1
2
3
4
5
6
7
8

Data Sheets
C-41
Sheet #32: Journal Dimensions

No. _________ Bearing No. _________ Bearing
Position 0 Deg. 90 Deg. Diff. Position 0 Deg. 90 Deg. Diff.
A A
B B
C C
D D
E E
F F
G G
H H
I I
J J
K K
L L
M M
N N
O O
P P
Q Q
R R
Taper Taper
*Average *Average

Data Sheets
C-42
Sheet #33: Bearing Orifice Inspection Checks

Bearing
No.
Orifice
Size
Comments
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Data Sheets
C-43
Sheet #34: Thrust Bearing (Overhung)

Parallelism Check ______
Thrust Plate Inspection ______
Collar to Shaft Fit ______
Check Thrust Nut Torque ______
Check Threads on Rotor ____
Babbitt Inspection ___
Runner Inspection ____
Wear Device Inspection ____
Screens & Orifices ____
Thermocouples Calib. ____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Thrust Bearing Data

A Shim
B Plate
C Shim
D Plate
E Runner
T Total

F Casing
T Total
(F Minus T)
Clearance

(By Float)
Clearance

Wear Device
G Shim
H Shim

Ball Torque
(Ft-Lb)

Data Sheets
C-44
Sheet #35: Thrust Bearing (Straddle)

Parallelism Check ______
Thrust Plate Inspection ______
Babbitt Inspection ______
Runner Inspection ____
Wear Device Inspection ____
Screens & Orifices ____
Thermocouples Calib. ____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Thrust Bearing Data
A Shim
B Plate
C Shim
D Plate
E Casing
T Total

F Rotor
T Total
(F Minus T)
Clearance

(By Float)
Clearance

Runout (.0005 TIR) Seal Rings
G Turbine End Generator End
H Seal Diam. (J)
Rotor Diam. (K)
Ball Torque (Ft-Lb) Clearance

Data Sheets
C-45
Sheet #36: Thrust Bearing (Independently Mounted-Tapered Land/CCW) Checks

Land
1 2 3 4 5 6 7 8 9 10 11 12
A
B
C
D
OD
E
F
G
H
J
Mean
K
L
M
N
P
ID
Q
Land has
Thermocouple
(Yes/No)

Percent*
*Actual width of land (flat) in percent of total land width.

Data Sheets
C-46
Sheet #37: Thrust Bearing (Independently Mounted-Tapered Land/CW) Checks

Land
1 2 3 4 5 6 7 8 9 10 11 12
A
B
C
D
OD
E
F
G
H
J
Mean
K
L
M
N
P
ID
Q
Land has
Thermocouple
(Yes/No)

Percent*
*Actual width of land (flat) in percent of total land width.

Data Sheets
C-47
Sheet #38: Thrust Assembly (Sample)

Thrust at Disassembly
Thrust at Assembly
Stack Check, Gov. Side
Stack Check, Gen. Side
Thrust Cage Movement

A
Position Readings
B
Position Readings
C
Position Readings
1
2
3
4
5
6

Data Sheets
C-48
Sheet #39: Thrust Bearing Thermocouple Measurements

Thrust Thermocouple Temperatures (F)
Turbine End Generator End
Thrust Oil
Temperatures (F)
Time* RPM Load
(MW)
Inlet Turb
Drain
Gen
Drain

*Fifteen Minute Increments

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-49
Sheet #40: Tilt Pad Bearing Oil Seal Ring and Shaft Dimensions

Shaft Diameter Seal Diameter Measured
Clearance
(average seal -
average shaft)
Design
0 Deg. 90 Deg. Average A B C Average Clearance Clearance
#1 Gov
#1 Gen
#2 Gov
#2 Gen

Data Sheets
C-50
Sheet #41: Thrust Cage Oil Seal Rings

Axial Clearance Radial Clearance
Thrust Cage
Groove Width
Thickness of
Oil Seal Ring
O.D.
Shaft Diam.
I.D.
Oil Seal Ring
Seal
Left
Side
Right
Side
Left
Side
Right
Side
Clr. A B C A B C Clr.
L/H Helix
Gov. End

R/H Helix
Gen. End

Data Sheets
C-51
Sheet #42: Bull Gear to Coupling Rabbet Fit Check

Turbine End
Diameter of Male Fit
Diameter of Female Fit

Generator End

Data Sheets
C-52
Sheet #43: Coupling Eccentricity Runout

B
Turbine End
Coupling
C
Generator
End Coupling
Difference Bolt # A
Turbine End
Journal
B
Generator
End Journal
Difference

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-53
Sheet #44: Rotor Radial Runout Checks
Rotor Identification _________________ Notes: 1. Mark positions 1-8 to agree with stamped degree marks on
rotor as shown in Figure 1.
2. Set indicator to 0 at number 1 position.
3. Indicate both journals and five planes along body (between
stages) of each rotor. See Figures 2, 3, and 4.
Rotor Checked: In Unit
Out of Unit
Check which end of rotor is at Turbine
face plate if placed in lathe Generator
Describe location of rotor supports Turbine End ____________________
Generator End ____________________

Area Indicated Position Numbers
Journal or Stage No. 1
0
2
45
3
90
4
135
5
180
6
225
7
270
8
315
1
0
A
B
C
D
E
F
G
H
J
K
L
M
N
P

Data Sheets
C-54
Sheet #45: Coupling Inspection Checks
Rotor Identification _________________ Notes: 1. For radial runouts, set indicator to read 0 at the number 1
position.
2. Mark positions 18 to agree with stamped degree marks on
rotor as shown in Figure 1.
Check which coupling Turbine End
Generator End

Position Numbers
Area Indicator 1
0
2
45
3
90
4
135
5
180
6
225
7
270
8
315
1
0
TE Journal
GE Journal
Coupling Periphery (A)
Coupling Bolt Face (B)
Coupling Back Face (C)
Coupling Rabbet (D)
Coupling Hub Dia. (E)

Thrust Runner Runout Check (if applicable)
Area Indicated 1
0
2
45
3
90
4
135
5
180
6
225
7
270
8
315
1
0
TE Journal
GE Journal

Coupling Dimensional Check
Location Actual Comments
Coupling Face Flatness (B)
Coupling Rabbet Dia. (D)
Coupling Rabbet Depth (F)

Data Sheets
C-55
Sheet #46A: Coupling Alignment Data Sheet

Data Sheets
C-56
Sheet #46B: Rotor Coupling Alignment Check Summary

Data Sheets
C-57
Sheet #47: Rotor Radial Position Tight Wire vs. Shaft
Turbine Section _______________________

Location ERAG Reading Ideal Rotor
Position
Shaft Readings

Data Sheets
C-58
Sheet #48: Oil Bore Radial Position

Comments:

Data Sheets
C-59
Sheet #49: Gland Bore Radial Position

Comments:

Data Sheets
C-60
Sheet #50: Rotor (Axial) Position Data

Instrument Travel forward From K Travel Aft from K Total Travel
Dial Indicator
Mic Plate
K Ref
Bearing Fillet

NOTE: Thrust bearing disassembled.

Limiting Factor Forward from K
Limiting Factor Aft from K

K Location: Turbine
MIC Plate
Bearing Fillet

Data Sheets
C-61
Sheet #51: Rabbet Fit of the No. 1 Coupling (Sample)

HP End

IP End

Data Sheets
C-62
Sheet #52: Rabbet Fit of the No. 2 Coupling (Sample)

Data Sheets
C-63
Sheet #53: Coupling Bolt Assembly Data
Coupling _________________________

Coupling Hole Diameter Clearance Stud Hole
TB. Side Gear Spacer Gen. Side
Stud
Diameter
TB. Side Gear Spacer Gen. Side
1 (M)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

Data Sheets
C-64
Sheet #54: Oil Deflector Check

Teeth Inspected ______
Journals Inspected ______
______
______
______
______
______
___
___
___
___
___
___
___
X Work Carried Out
N Not Done
NA Not Applicable
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Forward or Turbine End Aft or Generator End Deflector
Number
Journal
Diameter
Vertical Clear

Data Sheets
C-65
Sheet #55: Oil Rings

Teeth Inspected ______
Journals Inspected ______
______
______
______
______
______
___
___
___
___
___
___
___
X Work Carried Out
N Not Done
NA Not Applicable
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Forward or Turbine End Aft or Generator End Deflector
Number
Journal
Diameter
Vertical Clear

Data Sheets
C-66
Sheet #56: Rotor Oil Seal/Deflector Clearances (Sample)

Ring Location Top Bottom Right Side Left Side Design Radial
Clearance

Data Sheets
C-67
Sheet #57: Cylinder Support Block and Liner Clearances

Component A B C D Design
Clearance
Clearance

Data Sheets
C-68
Sheet #58: IP Turbine Inner Cylinder Bore Diameters

Data Sheets
C-69
Sheet #59: Bolt Stretch Chart

Location Bolt No. Bolt
Free
Length
Reqd
Stretch
Cold
MIC
Measure
Cold Full
MIC
Reading
Amount
to Turn
(Deg.)
Amount
to Turn
(Flats)
Stretch
Measure
Total
Stretch
Deg.
Turned to
Correct
Final
Measure
Final
Stretch

Data Sheets
C-70
Sheet #60: HP Cylinder Flange/Steam Line Flange

Steam Lead Gov. Side Left Steam Lead Gov. Side Right
Female
A
Male
B
Difference Female
A
Male
B
Difference
Top Top
Bot Bot
Gov Gov
Gen Gen

Steam Lead Gen. Side Left Steam Lead Gen. Side Right
Female
A
Male
B
Difference Female
A
Male
B
Difference
Top Top
Bot Bot
Gov Gov
Gen Gen

Data Sheets
C-71
Sheet #61: HP Inlet Steam Flange Bolt Stretch (Sample)

Bolt Free
Length
Cold
Length
Heat
Stretch
Total
Stretch
1
2
3
4
5
6
7

8

Side Desired Stretch Amount

Bolt Free
Length
Cold
Length
Heat
Stretch
Total
Stretch
1
2
3
4
5
6
7

8

Number of Nuts Replaced
Number of Bolts Replaced

Data Sheets
C-72
Sheet #62: IP Turbine and Inner Cylinder Sleeve/Bore Diameter (Sample)

Left 0 Deg. Left 90 Deg. Right 0 Deg. Right 90 Deg.
A
B
C

Left 0 Deg. Left 90 Deg. Right 0 Deg. Right 90 Deg.
A
B
C

Data Sheets
C-73
Sheet #63: LP Inner Cylinder Bolting and Half Joint Layout (Sample)

Data Sheets
C-74
Sheet #64: Nozzle Inlet Ring Clearances

Ring Location A B

Data Sheets
C-75
Sheet #65: HP Turbine Elevation Block Clearance (Sample)

Data Sheets
C-76
Sheet #66: IP Rotor Dimensions (Sample)

Outside Diameter
0 90
1C
1R
2C
2R
3C
3R
4C
4R
5C
5R
6C
6R
7C
7R
8C
8R
9C
9R
10C
10R
11C
11R
12C
12R
13C
13R
14C
14R
15C
15R
16C
16R
17C
17R
18C
18R
19C
19R
20C
20R
21C
21R
22C
22R
23C
23R

Data Sheets
C-77
Sheet #67: HP Cylinder Feeler Gauge Readings (Sample)

Data Sheets
C-78
Sheet #68: IP Rotor Runout (Sample)

Zeros
No. 1 Bolt
Hole
0 45 90 135 180 225 270 315
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

As Received

Final

Data Sheets
C-79
Sheet #69: IP Cylinder No. 1 Blade Ring Dimensions (Sample)

Data Sheets
C-80
Sheet #70A: IP Blade Ring Dimensions (Sample)

Data Sheets
C-81
Sheet #70B: IP Blade Ring Dimensions (Sample) cont.

Data Sheets
C-82
Sheet #71: IP Rotor Dimensions (Sample)

Data Sheets
C-83
Sheet #72: Main Operating Cylinder

Dimensional Checks ______
Ball and Socket Inspection ______
Ring Inspection ______
Housing Inspection ______
Pilot Valves and Bushing ______
______
______
____
___
____
____
____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Comments

Data Sheets
C-84
Sheet #73: Pilot Valve Assembly

Main Operating Cylinder Front Standard

Comments

Data Sheets
C-85
Sheet #74: Governor Drive

Governor Worm & Gear ______
Pre-Emerg. Gov. Worm & Gear ______
Gov. Gear Drive Assembly ______
Pre-Emerg. Gov. Gear Drive Asm. ______
Gov. Shaft and Bearings ______
Pre-Emerg. Gov. Shaft & Bearings ______
Main Gears (BFP Drive Front End) ______
Main Gear Bearings
(BFP Drive Front End) ______
Gov. Worm Bearings ______
Tach. Gen. Assembly ____
Shaft Extension Pad Bearing ___
Check Piping Connections ____
Tooth Contact ____
Backlash* ____
Pinion Spline Condition ____
Oil Passages ____
Worm Alignment ____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Drive Shaft Clearances
Measurement Gov. Drive Shaft Pre-Em. Gov. Drive Sh.
D* Backlash
Bushing ID
Shaft OD
E
Clearance
Bushing ID
Shaft OD
F
Clearance
G Thrust Clearance

Data Sheets
C-86
Sheet #75: Speed Relay

Comments

Data Sheets
C-87
Sheet #76: Pilot Valve and Bushing

Speed Governor & PV ______
Speed Gov. Bushing &
Housing Bore ______
Pre-Emerg. Gov. & PV Assm. ______
Pre-Emerg. Gov. Bushing &
Housing Bore ______
Backup Gov. PV & Bushing ______
____
___
____
____
____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Data Sheets
C-88
Sheet #77: Pilot Valve Assembly

Comments

Data Sheets
C-89
Sheet #78: Thrust Bearing Wear Detector

Notes: 1. Physical damage to nozzles. Yes No
2. Pressure: Increasing _______
Decreasing _______
3. Rotor thrusted __________________

Orifice
Size A

Orifice
Size B

P.S. Setting
Inactive
PSI

P.S. Setting
Active
PSI

X Dim.

Y Dim.

Data Sheets
C-90
Sheet #79: Throttle Valve Servomotor

Data Sheets
C-91
Sheet #80: Intercept Valve Servo Relays

Right Side
Left Side

Gov. Relay Trip Relay
A Cyl. Sleeve I.D.
Valve O.D.
Clearance
B Cyl. Sleeve I.D.
Valve O.D.
Clearance

Data Sheets
C-92
Sheet #81: Intercept Valve Servo

Data Sheets
C-93
Sheet #82: Intercept Valve Servo and Test Piston

Comments

Data Sheets
C-94
Sheet #83: Intercept Valve Servo Pilot Piston and Guide

Comments

Data Sheets
C-95
Sheet #84: Reheat Valve Servo and Pilot Pistons

Comments

Data Sheets
C-96
Sheet #85: Reheat Valve Servo Dump and Operating Pistons

Comments

Data Sheets
C-97
Sheet #86: Auto Stop Trip Assembly (Sample)

Data Sheets
C-98
Sheet #87: Load Limit (Low Load)

Data Sheets
C-99
Sheet #88: Load Limit (High Load)

Data Sheets
C-100
Sheet #89: Auxiliary Governor

Data Sheets
C-101
Sheet #90: Main Governor

Data Sheets
C-102
Sheet #91: Governing Valve Servomotor

Data Sheets
C-103
Sheet #92: Backup Pilot Valve Relay Assembly

Data Sheets
C-104
Sheet #93: Quill Shaft Inspection Form

1 2 3 4 5 6 7
Diam.
TIR

Comments

Data Sheets
C-105
Sheet #94: Main Oil Pump Simple Suction

Mechanical Condition ______
Internal Clearances ______
Ring Condition and
Clearance ______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Data Sheets
C-106
Sheet #95: Main Oil Pump-Double Suction

Bearing Condition and
Clearance ______
Steady Bearing Force
and Movement Checks ______
______
______
______
______
______
______
______
______
______
______
______
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Data Sheets
C-107
Sheet #96: Turbine Shaft Main Oil Pump

I.D.
O.D
A Seal Ring L.H.
Helix
Clear.
I.D.
O.D.
B Seal Ring R.H.
Helix
Clear.
I.D.
O.D.
C Seal Ring L.H.
Helix
Clear.
I.D.
O.D.
D Seal Ring R.H.
Helix
Clear.
I.D.
O.D.
Gov. Impeller
Sleeve Turb.
End. R.H. Helix Clear.
I.D.
O.D.
E
Gov. Impeller
Sleeve Gov.
End. L.H. Helix Clear.
R/S F
L/S
R/S H
L/S
R/S I
L/S
R/S J
L/S
R/S K
L/S
R/S L
L/S
R/S M
L/S
R/S N
L/S
R/S O
L/S
R/S P
L/S
R/S Q
L/S
R/S R
L/S
R/S S
L/S
R/S T
L/S
R/S

U
L/S

Stub Shaft Runout

Data Sheets
C-108
Sheet #97: Auxilary Pump-Turbine Driven

Bearing Condition ______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
______
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Data Sheets
C-109
Sheet #98: Oil Pump-Motor Driven

Data Sheets
C-110
Sheet #99: Oil Pump-Motor Driven

Impeller Inspection ______
Wear Ring Inspection ______
______
______
______
______
______
______
______
Bearing Inspection ______
Coupling Checked ______
______
______
______
______
______
______
______
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant
Type: ____________________________
(TGOP, MSP, EBOP, etc.)

Bearing Clearance A B
Bearing ID
Journal ID
Clearance
Thrust

Wear Ring Clearance C D
Wear Ring ID
Impeller OD
Clearance

Data Sheets
C-111
Sheet #100: Control Valve Stems and Bushings

Disc Inspection ______
Stem Inspection ______
Bushing Inspection ______
Stud Inspection ______
Nut Inspection ______
Body Inspection ______
______
______
______
______
______
______
______
______
______
______
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant
Note: Stem and bushing diameters should be recorded both before and after cleaning.
Try bar diameters must be recorded.
Before
Cleaning
After
Cleaning
Before
Cleaning
After
Cleaning
Valve Clearances
B B E E
Bushing ID
Stem OD
Valve No.
_______
Try Bar Dia.
_______
Clearance
Bushing ID
Stem OD
Valve No.
_______
Try Bar Dia.
_______
Clearance
Bushing ID
Stem OD
Valve No.
_______
Try Bar Dia.
_______
Clearance
Bushing ID
Stem OD
Valve No.
_______
Try Bar Dia.
_______
Clearance

Stem Runout A C D F
Valve No.
Valve No.

Data Sheets
C-112
Sheet #101: Control Valve Crossheads and Discs

Seat Inspection ______
Seat Contact Check ______
Stand Inspection ______
______
______
______
______
______
______
______
______
______
______
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Crosshead Guide & Bushing
Valve
No. No. No. No.
Bushing ID
Guide OD
Clearance

Stem to Crosshead Clearance
Valve
No. No. No. No.
Bushing/ Crosshead ID
Stem OD
Clearance

Valve to Stem Clearance
Valve
No. No. No. No.
Upper Sleeve ID (A)
Upper Valve OD (A)
Clearance
Lower Sleeve ID (B)
Lower Valve OD (B)
Clearance

Lift

Data Sheets
C-113
Sheet #102: Steam Chest Plug Dimensions

Left Side
0 Deg.
Left Side
90 Deg.
Right Side
0 Deg.
Right Side
90 Deg.
Design
Clearance
A Chest I.D.
B Ring O.D.
Clearance
C Ring I.D.
D Plug O.D.
Clearance

Data Sheets
C-114
Sheet #103: Governor Valve Lift Rods and Bushings

Lift Rod Diameter and Clearance
A D Clearance B C E Clearance Run-out
A B C
Right Side Gov. End
Gen. End
Left Side Gov. End
Gen. End

Data Sheets
C-115
Sheet #104: Governor Valve Seat Elevation

Valve No. Left Side Valve No. Right Side

Data Sheets
C-116
Sheet #105: Steam Chest Governor Valve Settings

Left Side Right Side
Valve
No.
Design
Valve
Travel
Design Valve
Travel Adjusted
for Seat
Elevation
Actual
Valve
Travel
D
Dim.
Valve
No.
Design
Valve
Travel
Design Valve
Travel Adjusted
for Seat
Elevation
Actual
Valve
Travel
D
Dim.

Data Sheets
C-117

Sheet #106: Main Stop Valve

Pressure Seal Head ______
Head Inspection ______
Strainer Inspection ______
______
______
______
______
______
______
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Before
Clean
After
Clean
Before
Clean
After
Clean
Before
Clean
After
Clean
Before
Clean
After
Clean
Valve Clearances
B B C C E E H H
Bushing D
Stem OD
Valve No.
______
Try Bar Dia.
______
Clearance
Bushing D
Stem OD
Valve No.
______
Try Bar Dia.
______
Clearance

Stem Runout A B C D E F
Valve No.
Valve No.

Bypass Valve Lift Lift
Valve No.
Valve No.

Data Sheets
C-118
Sheet #107: Main Stop Valve Full Arc Bypass Controlled

By-Pass Location Valve Lift
A
B
C

Data Sheets
C-119
Sheet #108: Main Stop Valve Bypass Type

Data Sheets
C-120
Sheet #109: Throttle Valve/Intercept Valve Clearance (Sample)

Data Sheets
C-121
Sheet #110: Throttle Valve Clearance Data (Sample)

Design
Clearance
Left Valve Right Valve
Bushing I.D.
Stem O.D.
A
Clearance
Bushing I.D.
Stem O.D.
B
Clearance
Bushing I.D.
Stem O.D.
C
Clearance
Bushing I.D.
Stem O.D.
D
Clearance

Stem Runout A B C D Design
Left Side
Right Side

Data Sheets
C-122
Sheet #111: Throttle Valve Squareness Check

Left Throttle Valve Right Throttle Valve
Left Side Right Side Gov. End Gen. End Left Side Right Side Gov. End Gen. End
Clearances

Data Sheets
C-123
Sheet #112: Intercept Valve Clearance Data

Left Valve Right Valve Design
Clearance
As Found As Left As Found As Left
Bushing I.D.
Stem O.D.
A
Clearance
Bushing I.D.
Stem O.D.
B
Clearance
Bushing I.D.
Stem O.D.
C
Clearance

Stem Runout A B C Design
Left Side
Right Side

Note: Was Stem Replaced? Yes
No

Data Sheets
C-124
Sheet #113: Combined Reheat Stop-Intercept Valve

Stem Inspection - Upper ______
Stem Inspection - Lower ______
Main Seat Inspection ______
Intercept Valve Disc Inspection ______
Reheat Stop Valve Disc Inspection ____
Outer Disc Contact Check _______
Inner Disc Contact Check ____
Strainer Inspection ____
Linkage Inspection ____
Equalizer Valve ____
Inspection of Equalizer ____
Valve on #2 CRV ____
Pressure Seal Head ____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Left Side Valve Right Side Valve
Valve Clearances Before
Cleaning
After
Cleaning
Before
Cleaning
After
Cleaning
Bushing ID
Crosshead OD
L
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD
B
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD
D
Clearance
Bushing ID
Stem OD
H
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD
J
Clearance
Balance
Chamber ID

Seal Rings OD
Clearance

E

Ring Axial
Clearance

Stem Runout A C F G I K
Left Side
Right Side
Stem Length In.

Data Sheets
C-125
Sheet #114: Intercept Valve Separately Mounted

Pilot Valve Inspection _______
Seat Contact Check ____
____
____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Cleaning
After
Cleaning
Before
Cleaning
After
Cleaning
Bushing ID
Stem OD
A
Try Bar Dia.
________
Clearance
Guide
Bushing ID

Seal Ring
OD

B
Clearance
Ring Axial
Clearance

Bushing ID
Stem OD
C
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD
D
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD

E
Try Bar Dia.
________
Clearance

Stem Runout A C D E F
Left Side
Right Side

Data Sheets
C-126
Sheet #115: Intercept Valve Shell Mounted

Pilot Valve Inspection _______
Seat Contact Check ____
____
____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Cleaning
After
Cleaning
Before
Cleaning
After
Cleaning
Bushing ID
Stem OD
B
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD
D
Try Bar Dia.
________
Clearance
Guide
Bushing ID

Seal Rings
OD

Clearance
E
Ring Axial
Clearance

Bushing ID
Stem OD
F
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD

G
Try Bar Dia.
________
Clearance

Stem Runout A C D F
Left
Right

Data Sheets
C-127
Sheet #116: Reheat Stop Valve Separately Mounted

Head ______
Bypass Line Inspection ______
Pressure Seal Head ____
Rocker Arm Inspection _______
____
____
____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Cleaning
After
Cleaning
Before
Cleaning
After
Cleaning
Bushing ID
Stem OD
B
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD
D
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD
F
Try Bar Dia.
________
Clearance
Bushing ID
Stem OD

G
Try Bar Dia.
________
Clearance

Stem Runout A C E F G
Left Side
Right Side

Data Sheets
C-128
Sheet #117: Reheat Stop Valve and Servomotor

Data Sheets
C-129
Sheet #118: Ventilator Valve

Casing Inspection ______
Main Seat Inspection ______
Internal Seat Inspection ______
Main Disc Inspection ____
Internal Disc Inspection _______
Piston & Ring Inspection ____
Air Cylinder Inspection ____
Piston Rod Inspection ____
Piston Gasket Inspection ____
Linkage & Spring Inspection ____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
MP Mag. Particle
UT Ultrasonic
PT - Penetrant

Data Sheets
C-130
Sheet #119: Emergency Blowdown Valve

Data Sheets
C-131
Sheet #120: Valve Gasket Check

Gasket Thickness
Bolts Replaced

Valve Body
Female
Valve Cover Male Difference Runout
Right Side 1
2
3
4
Left Side 1
2
3
4

Data Sheets
C-132
Sheet #121: Screen and Valve Dimensions

Valve # _________
0 Deg. 180 Deg.
A I.D.
A O.D.
B O.D.
C
D
E Body
E Bonnet Plus
Screen

Data Sheets
C-133
Sheet #122: Valve Couplings

Main Stop Intercept Reheat
Left Right Left Right Left Right
A
B
C
Cylinder Lift
Stem Clear

Data Sheets
C-134
Sheet #123: Cam Rods

Bearing Bearing Bearing Bearing Bearing
Journal Journal Journal Journal Journal
Clear Clear Clear Clear Clear

Bearing Bearing Bearing Bearing Bearing
Journal Journal Journal Journal Journal
Clear Clear Clear Clear Clear

Runout
Left to Right at the Bearing Area
1 2 3 4 5
Upper Cam Rod
Lower Cam Rod

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-135
Sheet #124: Control Valve Settings (Sample)

Valve No. When This
Valve Is
This Valve
Is Up .030"
Total Travel Piston
Travel
Roller Clear
Expected #1 (T) #2
As Found
As Left
Expected #2 (B) #3
As Found
As Left
Expected #3 (T) #4
As Found
As Left
Expected #4 (B) #5
As Found
As Left
Expected #5 (B) #6
As Found
As Left
Expected #6 (T)
As Found
As Left

Cold Settings
Cam Clearances (T) Top
Pad Clearances (B) Bottom

Total Piston Stroke

Comments: __________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Data Sheets
C-136
Sheet #125: Valve Gasket Compression

Main Stop Valve Intercept Valve
Left Right Left Right
Male Female Male Female

0 0
90 90
180 180
270 270

Compression Compression

Reheat Stop Valve Control Valves
Left Right No. 3 No. 4

0 0
90 90
180 180
270 270


Control Valves Control Valves
No. 3 No. 4 No. 5 No. 6

0 0
90 90
180 180
270 270


Comments: __________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Data Sheets
C-137
Sheet #126: Stem Seal Regulator

Data Sheets
C-138
Sheet #127: Generator Information Sheet 1

Generator Information
Rating _____________ KVA Code __________ Stator No. ____________ Original Service Date _____________
Stator ____________ KV _________ AMPS _________ Max. H2 Press _________________________________
Stator Winding ____________ Slots ____________ Circuits ____________
Insulation Asphalt Micaral Micaral II
Cooling Conventional Conductor Single Pass Double Pass
Cooling Type Air Hydrogen Oil Water
Support System Conventional Tetraloc Modified Tetraloc
Blocking Maple Textolite Felt
Ties Flax. Glass Cord. Glass Roving
End Winding Radius Strips Sausages Z-Rings
Series Loops Liquid Cooled
Wedge Flat Split Camelback Piggyback Other
Sidesprings None 90 Mil 200 Mil

Field No. _______________ Forging No. ______________ Volts _____________ Amps __________________
Speed _________________ RPM _____________________ Poles ___________________________________
Field Cooling Conventional Radial Diagonal
Bushing Cooling Conventional Gas Water
End Winding Nose Rings Tee Bolts Inner Axials

Type of Inspection Field Removed Endshelds Removed

Data Sheets
C-139
Sheet #128: Generator Information Sheet 2

Comments
Inner Oil Deflector Insulation _______________________________________________________________
H2 Seal Holder Insulation _______________________________________________________________
Upper and Lower Bearing Insulation _______________________________________________________________
Outer Oil Deflector Insulation _______________________________________________________________
Insulated Coupling Insulation _______________________________________________________________
Previous Vibration Problems in Field _______________________________________________________________

Data Sheets
C-140
Sheet #129: Hydrogen Seal Oil System Inspection

Codes
X Work Carried Out NA Not Applicable V Visual Inspection U - Unsatisfactory
N Not Done C See Comments S Satisfactory
Inspections & Checks
System Type:
a. Vacuum
b. Scavenging
Main Seal Oil Pump ______
Emergency Seal Oil Pump ______
Gas Side Drain Float, Trap
and Valve ______
Vacuum Pump ______
Drain Enlargement ______
Relief Valves ____
Liquid Detectors & Alarms ____
Auto Pump Start & Alarm
Tests ____
Regulating Valves ____
Oil Filters ____
Coolers ____
Seal Oil Pressure Gauges
at Unit CL ____
High Level Alarm on
H2 Detraining Tank _____
Gauge Calibration _____
Seal Casing Assembly _____
Joint Clearances _____
Oil Grooves Clear? _____
_____
_____
_____

Seal Measurements (To Nearest .001")
Turbine End Collector End Position
Air H2 Air H2
1
2
3
4
5
6
Average
Seal Shaft Dia.
H2 Seal Spring Measurements
Turbine End Collector End
Upper Lower Upper Lower
Length (In. + 1/16)
Wire Diameter
Coil Diameter
Gradient (#/In)

Testing Data:
A. Seal Oil Flow __________ GPM
B. Hydrogen Pressure __________ psi
C. Unit Speed __________ RPM

Data Sheets
C-141
Sheet #130: Hydrogen Seal Inspection

Data Sheets
C-142
Sheet #131: Generator Hydrogen Seal Clearances

End
Runout
Flange
Face
Groove
Face
Diff. Groove
Width
Ring
Width
Diff. Ring
Flatness
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10

Average Clearance

H2 Seal Ring
A B C D E Avg. Journ. Clear.
Air
Side

H2
Side

Labyrinth Seals
Row A C D Avg. Journ. Clear.
2
6
3

Data Sheets
C-143
Sheet #132: Generator Seal Settings

Labyrinth Seal

Turbine End Clearance
Left Side Bottom Right Side
A
B
C

Exciter End Clearance
Left Side Bottom Right Side
A
B
C

Note 1
Insulated bolts torque to 368 ft-lbs. Torquing procedure
begins on the bottom center/top center bolt and alternates
side to side until reaching the horizontal joint.
*** Three intervals (passes) should be used to reach the final
torque.
1st pass = 100 ft-lbs
2nd pass = 275 ft-lbs
3rd pass = 368 ft-lbs

Data Sheets
C-144
Sheet #133: Generator Journal Diameters

1 2 3 4 5
A
B
C

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-145
Sheet #134: Generator Journal Diameters

Data Sheets
C-146
Sheet #135: Hydrogen Gas System Inspection

H2 Supply Disconnection
Spool Piece Removal ______
Bottles Disconnected ______
Purity Meter Calibration ______
Purging Gas Analyzer Calibration ______
Annunciator Alarms and Drop
to Control Room ______
Fan Differential Press Gauge ______
Calibration of All Gauges ______
CO2 Supply Disconnection
Spool Piece Removal _______
Bottles Disconnected ____
____
____
____
____
____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
S Satisfactory
U - Unsatisfactory

Hydrogen Consumption Design Actual
Prior to Outage
Air Test Equivalent Hydrogen Consumption

Comments: __________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Data Sheets
C-147
Sheet #136: Stator Cooling System Inspection

Main Coolant Pumps ______
Reserve Coolant Pumps Start ______
Deionizer and Resin ______
Storage Tank ______
Filters and Strainers ______
Coolers ______
Proportioning Valve ______
Conductivity Meter and Cells ____
Runback Circuit Verification ____
Calibration of All Gauges ____
Vacuum Breaker and Relief ____
Valve Operation ____
System Protective Alarm Circuitry ____
Calibration of All Alarm Settings ____
X Work Carried Out
N Not Done
NA Not Applicable
C See Comments
V Visual Inspection
S Satisfactory
U - Unsatisfactory

Additional Data: Initial Final
Water Conductivity _______________________________________________
Resin Source _______________________________________________
Resin Batch Number _______________________________________________
Resin Replacement Data _______________________________________________

Comments: __________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Data Sheets
C-148
Sheet #137: Generator Air Gap Baffle Clearances

Data Sheets
C-149
Sheet #138: Generator Fan Clearances

Data Sheets
C-150
Sheet #139: Blower Blade Clearances

Top Left Top Right Bottom Left Bottom Right
A
B
C
D
E
F

Data Sheets
C-151
Sheet #140: Exciter Armature Inspection Form

1 2 3 4 5 6 7 8
Diam.
TIR

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-152
Sheet #141: Exciter Reduction Gear Bearing and Shaft Dimensions

Casing
Bore
BRG.
O.D.
Seal
Bore
Shaft
O.D.
Clear Parts Replaced
1A
1B
1C
2A
2B
2C
3A
3B
3C
4A
4B
4C

Data Sheets
C-153
Sheet #142: Exciter Bearing Inspection Form

Plane A Plane B Plane C Accept Reject
Inboard
Middle
Outboard

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-154
Sheet #143: Exciter Pinion Gear Inspection Form

0 Deg. 90 Deg.
Diameter/Runout Diameter/Runout Accept Reject
A
B
C
D
E

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-155
Sheet #144: Exciter Bull Gear Inspection Form

0 Deg. 90 Deg.
Diameter/Runout Diameter/Runout Accept Reject
A
B
C
D
E

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-156
Sheet #145: Exciter Oil Seal Inspection Form

Blade Number Plane A Plane B Plane C Accept Reject
1
2
3
4

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-157
Sheet #146: Exciter DC Motor/Generator Gap Inspection

Incoming Readings
Position #1 Position #2 Position #3 Position #4
Drive End
Opposite Drive End

Final Readings
Position #1 Position #2 Position #3 Position #4
Drive End
Opposite Drive End

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-158
Sheet #147: Exciter DC Drop Test Inspection Form

Shunt Winding Position #1 Position #2 Position #3 Position #4
F1 F2
F3 F4
F5 F6
F7 F8

Megger Readings
Shunt Winding F1 F2 F3 F4 F5 F6 F7 F8
@ 500 VDC

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-159
Sheet #148: Exciter Seal to Journal Setting

All readings taken viewing the pedestal facing the exciter.
Top of Seal Bottom of Seal Left of Seal Right of Seal
Inboard Seal
Outboard Seal

Comments: ____________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________

Data Sheets
C-160
Sheet #149: Generator/Exciter Rotor Seal and Collector Area

Recommended Action Fit Size
0 Deg. 90 Deg.
Surface
Condition
Turn Polish
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R

Data Sheets
C-161
Sheet #150: Exciter Coupling Alignment Form

Incoming Alignment Readings
Top Gap Bottom Gap Left Gap Right Gap
0 deg.
90 deg.
180 deg.
270 deg.

Final Alignment Readings
Top Gap Bottom Gap Left Gap Right Gap
0 deg.
90 deg.
180 deg.
270 deg.

Data Sheets
C-162
Sheet #151: Protective Device and Pre-Operational Checks Sheet 1
Codes: X - Work Carried Out N - Not Done NA - Not Applicable
Supervisory Instrument Checked and/or Calibrated
1. Eccentricity _____________
2. Differential expansion _____________
3. Vibration probes _____________
4. Shell expansion _____________
5. Speed/valve position _____________

Vacuum Trip
1. Valves trip with vacuum trip _____________
2. Trip settings
1. High __________ In. Hg Abs
2. Low __________ In. Hg Abs
3. Low vacuum alarm setting ________ In. Hg Abs

Thrust Wear Indicator
1. Trips checked ___________ Alarms checked
2. Thrust wear detector (+) _________ Trip point
(-) _________ Trip point

Solenoid Trip Tested Remote Trips
Valves Checked for Proper Operation
1. Main stop ______
2. Control ______
3. Reheat Stop ______
4. Intercept ______
5. 1
st
Extraction ______
6. 2
nd
Extraction ______
7. Blowdown ______
8. Ventilator ______
9. Equalizer ______
10. Steam seal feed valve ______
11. Steam seal unloading ______
12. Steam seal diverting ______
13. Exhaust spray ______
14. Steam lead drains ______
15. Non-return ______

Shell and Valve Thermocouple Checked _______
Thermostats Checked _______
1. Exhaust hood temperature ________
2. Extration lines ________

Generator RTDs Checked ________
Stator Bars Coolant TCs Checked ________
Shaft Grounded Brushes Inspected ________
Lube Oil System ________
1. Level alarm checked ________
2. Auto. sequential pump starting checked ________
3. Oil tank vacuum checked
______ In. H2O ________
4. Bearings sight flows checked ________
5. Extration relay dump valve checked ________

EHC System
1. Auto. pump starting checked ________
2. All alarms checked ________
3. All filters and dryers checked ________
4. Leak test coolers ________
5. Fluid sample analyzed ________
6. Test high-pressure trip system ________
7. Test 24-volt DC system ________
8. Test mechanical trip valve ________
9. Check for proper operation of valve
operator ________

Seal Oil System
1. Auto. pump starting checked ________
2. Liquid level alarms checked ________
3. Press. and diff. alarms checked ________
4. Seal oil flows checked ________

Data Sheets
C-163
Overspeed Governor
1. Tested ______ Date ____________________________ Witnessed By _________________________________
Trip Speeds ______________ Test 1 ________________ Test 2 ________________ Test 3 ________________
2. Oil trip tested _____________
3. Minimum oil tripping tested _________ Trip speed
4. Back-up overspeed tested _________ Trip speed
5. On-line governor tested/checked _________ (Exerciser)
6. Extraction non-return valves satisfactorily operated _______

Operating Governor
1. High speed stop __________ RPM
2. Low speed stop __________ RPM
3. Regulation __________ %

Pre-Emergency Governor
1. IV begin to close __________ RPM
2. IV half closed __________ RPM

Underspeed Release
1. Release __________ RPM
2. Reset __________ RPM

Initial Press. Regulator
1. Rated stem press. __________ psig
2. Valves start close __________ psig
3. At no load setting __________ psig
4. No load stop setting
inches hydraulic stroke __________

Thrust Wear Indicator
1. Trips checked _______ Alarms checked
2. Thrust wear detector (+) ________ Trip Point
(-) ________ Trip Point

Bearing Temp. Rise
1. Cooler in _________ F out ________ F
2. Highest bearing no. _______ temp. _______ F
3. Thrust bearing TE _______ F GE ________ F

Lube Oil System
1. Bearing header pressure ___________
2. Shaft suction pump press. ___________
3. Hydraulic press.

Stop Valves Leakage Checked ___________
Control Valves Leakage Checked ___________
Intercept Valves Leakage Checked ___________
Gen. RTDs Balanced on Cold Gas ___________
Stator Bar Coolant TCs ___________
1. At no liquid Highest TC No. ___________ F
Capacity Low TC No. ___________ F

2. At full load Highest TC No. ___________ F
Low TC No. ___________ F

Shaft Voltage Check
A. AC Voltage ______________ Volts
B. DC Voltage ______________ Volts
C. Measured at ______________
D. Type Meter ______________

Data Sheets
C-164

Stator Cooling System
1. Auto. pump starting checked _____________
2. Systems alarms checked _____________
3. Conductivity cells inspected _____________
4. Governor run back checked _____________

Hydrogen System
1. Alarms all checked _____________
2. Purity analyzer calibrated _____________
3. System leak checked _____________
4. Leakage ___________ cu. ft./day

Bearing and Hydrogen Seal Insulation Check
1. Bearing resistance ___________ ohms
2. Hydrogen seal resistance ___________ ohms
3. Exciter coupling resistance ___________ ohms
4. Inner and outer oil deflector ______ Inner ohms
______ Outer ohms

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Angle

Gen End
AMP

Angle

Coupling
TB End
AMP

Angle

BRG

AMP

Angle

BRG

AMP

Angle

Gen End
AMP

Angle

Coupling
TB End
AMP

Angle

BRG

AMP

Angle

BRG

AMP

Filter

Date, Time

Load/Speed

Comments: ______________________________________________________________________________________________
_______________________________________________________________________________________________________
Rotor Critical Speeds ____________________________________________________________________________________
Frequency Scan -_________________________________________________________________________________________
Equipment Used - ________________________________________________________________________________________
Equipment Lag Angle -_____________________________________________________________________________________
Zero Ref Mark Color - _____________________________________________________________________________________
Inlet Oil Temp -___________________________________________________________________________________________

Data Sheets
C-166
Sheet #155: Balance Weight Locations

Balance Plane Location_____________________________________

Mark Block if Weight is
Installed
Mark Block if Weight is
Installed
1 31
2 32
3 33
4 34
5 35
6 36
7 37
8 38
9 39
10 40
11 41
12 42
13 43
14 44
15 45
16 46
17 47
18 48
19 49
20 50
21 51
22 52
23 53
24 54
25 55
26 56
27 57
28 58
29 59
30 60

D-1
D
FOREIGN MATERIAL EXCLUSION GUIDANCE
D.1 Introduction and Purpose
The purpose of this appendix is to supplement the component-specific guidance provided in
Section 2.11 of this report with programmatic guidance that plant/site personnel can use to
develop or enhance FME programs. Operating experience clearly demonstrates that foreign
material represents a real threat to personnel safety, radiological safety, nuclear safety, and plant
reliability. Avoiding the consequences of events of this nature requires the implementation of
controls and good work practices that effectively minimize the potential for foreign material
intrusion. This appendix provides programmatic guidance for preventing the introduction of
foreign material into plant systems and components, as well as measures to implement in the
event that foreign material intrusion occurs.
In general, this appendix provides guidance for establishing requirements that would prevent the
introduction of foreign material, such as dirt, debris, and tools, into open systems or components.
The program describes a method for controlling and accounting for materials, tools, and parts to
preclude their uncontrolled introduction into an open system or component during maintenance,
modification, or inspection activities. Additional guidance is provided to recover from the
intrusion of foreign material.
Preventing the introduction of foreign material into systems and components (electrical and
mechanical) avoids the associated damaging effects such as corrosion, fuel damage, component
malfunction or failure, chemistry changes, increased radiation levels, and personal injury.
In general, an FME program should apply to systems and components of the plant for which
intrusion of foreign material could result in degraded performance. The program should be used
on piping, vessels, tubing, electrical equipment, and mechanical equipment where the
introduction of foreign material could adversely affect the equipment. Normal good
housekeeping practices apply to activities that will not introduce foreign materials. It should not
be the intent of the FME program to institute additional controls on work activities that are
procedurally controlled or that by their nature do not breach a system or increase the potential for
foreign material intrusion.

Foreign Material Exclusion Guidance
D-2
D.2 Definitions
D.2.1 Glossary of Key Terms
access control point The single point of control for entry and exit of personnel and material
for an FMEA zone.
appropriate personnel The immediate supervisor or other designated responsible employee.
area owner The individual or individuals assigned the responsibility for a work area.
breach To render the integrity of a component or system ineffective to the point where foreign
material could enter. Breaches include physical openings in mechanical systems as well as cases
where the interior of instrumentation or electrical equipment is exposed (for example, a
switchgear cabinet door is opened; the cover to an electrical enclosure is removed; etc.).
buffer zone An area established immediately adjacent to critical or sensitive FMEAs as
appropriate or practicable. This area is a zone that is maintained free from material that has the
potential to be tracked or blown into the FMEA or to fall into it. This area should be monitored
and controlled to prevent material (whether from flying debris from overhead or a nearby area)
from entering the FMEA or stationary items from being tracked (or kicked) into it. Examples:
Crane work overhead, welding or grinding near the barrier, portable dirt or wires carried by foot
into the area. Debris in the buffer zone is not an FME violation, but it must be cleaned up or
removed immediately upon identification.
clean area A space or enclosure such as a tent or a roped off or partitioned area in which the
air is free from foreign particles (that is, no grinding, welding, or sand blasting). A clean plastic
bag or sleeve meets the requirements for a small clean area.
cleaning as you go The process of cleaning up foreign material in local areas around
particulate-producing operations such as machining, grinding, welding, or cutting that is
accomplished while those activities are in progress (in addition to at the end of the task).
cleanliness The condition of removing contamination to an acceptable level and maintaining
an acceptable level.
cleanliness classification The requirements and administrative controls to maintain system
cleanliness during maintenance and modification activities.
consumables Items expended during work in the FMEA (for example, cleaning solvents)
contamination Any undesirable foreign material on the surface of an item, in the atmosphere,
or in process liquids or gases.
controlled plant equipment Structures, systems, and components that are safety-related,
whose functions impact the plant safety analysis, or that are subject to special considerations

D-3
based upon management discretion (for example, considerations given to licensing basis, the
Maintenance Rule, personnel safety, equipment availability, commercial risk, etc.).
fail safe A condition that exists when equipment or material cannot enter a system or
component due to the equipment or material being too large to fit through any breaches or the
equipment or material being securely mounted in place. Equipment or material that is breakable
and/or contains easily dislodged parts small enough to enter a breach is generally not considered
fail safe.
flush or filter cloth Cloth through which flushing fluid is passed to determine the acceptability
of a system or component flush.
flushing As used in the context of this procedure, flowing fluid or gas through a component or
system at adequate velocity to suspend and carry away anticipated contaminants.
FME condition An FME-related error that did not affect a system or component; this includes
administrative errors. This category provides information to assess FME programmatic needs.
FME device An internal device (such as a temporary dam and cover, pipe plug, etc.) or
external opening cover installed to prevent foreign material intrusion.
FME event A condition involving or resulting from inadequate implementation of FME
program controls. FME events can often fall into various categories based upon their actual or
anticipated consequences.
FME monitor - An individual assigned to control access to a particular FMEA and to maintain
logs for material and personnel accountability.
FME significant event An FME-related event that resulted in personnel injury, significant
plant equipment damage, fuel failure, or loss of generation.
FME vulnerability An FME-related implementation error or as-found condition thatif not
detectedcould pose a risk of personnel injury, plant equipment damage, fuel failure, or loss of
generation or that is the result of inappropriate human behavior during a work activity. This
includes events that required evaluations in lieu of retrieval.
FMEA boundary A physical boundary established at or around a work area, usually
consisting of barrier materials and signs visibly identifying the area as an FMEA.
FMEA dedicated monitor A person who is assigned responsibility for monitoring an FMEA.
The dedicated monitor has no other assigned duties. The dedicated monitors duties are to log
tools, materials, and so forth in and out of the FMEA zone and to ensure that personnel sign in
and out of the FMEA zone according to the site or station procedures.
FMEA tool and parts log A log used to keep track of items, tools, and partsincluding their
conditionthat are moved in and out of an FMEA.

D-4
foreign material Any material that is not part of a system or component as designed. Foreign
material includes any item that could adversely affect the integrity or intended operation of the
system or component, including dirt, debris, broken or missing parts, oil, slag, tools, rags,
chemicals, lapping compounds, grinding particles, paint chips, tie wraps, lugs, stripped
insulation, and leak sealant compounds.
foreign material exclusion (FME) The actions taken to prevent damage to plant systems and
equipment as a result of the introduction of foreign material. These actions include the work
planning process, controls on the performance of work, cleanup/foreign material removal, and
work area close out. The requirements for foreign material exclusion are established herein and
must be incorporated into the applicable procedures governing the work.
foreign material exclusion area (FMEA) An area at or around a system or component breach
or a nuclear fuel storage/handling area that requires specific controls to prevent the introduction
of foreign material during the performance of maintenance, modifications, testing, and/or
inspections. The FMEA is an established area to control material, tools, andin some
instancespersonnel movement in and around open systems or components.
foreign material exclusion boundary The boundary for the area that is subject to foreign
material exclusion controls. The boundary may be defined by barrier tape as in the case of
FMEAs or by an opening in a piece of equipment such as a valve bonnet flange or motor control
center door.
foreign material exclusion monitor The individual responsible for controlling personnel,
materials, and tools entering the FMEA.
immediately retrievable Foreign material (within a system or component) that meets all of the
following criteria:
The material can be observed.
Recovery will require no more than a momentary interruption in task performance.
Recovery efforts are unlikely to inadvertently result in the item migrating to a less
accessible area.
Recovery of the item will not expose personnel to an industrial safety or radiological
hazard (for example, items found in contaminated systems may be highly radioactive).
implementer The individual or individuals assigned the responsibility for performing a work
activity.
loss of FME control A condition deemed to exist whenever any of the following
circumstances occurs:
Foreign material is found within a component, enclosure, or system (including open-air
systems such as the spent fuel pool).
Foreign material that is not immediately retrievable is introduced into a component,
enclosure, or system (including open-air systems such as the spent fuel pool).

D-5
A component is found to be missing parts that most likely remain within a system.
Parts of tools or equipment used within an FMEA are identified as missing.
Material recorded on FME log sheets can not be accounted for.
Material that was not documented is found within an FMEA.
Internal FME barriers (for example, pipe dams) have failed, or FME barriers are damaged
or missing while the FMEA is unattended.
External FME covers are damaged, removed, or displaced while an FMEA is unattended.
Control log discrepancies cannot be immediately resolved.
permanent FME area Areas such as, but not limited to, spent fuel storage, drywell, torus,
refuel floor including moisture separator, and reactor cavity with the head removed.
power plant boundaries or equipment Systems and components that perform a direct
function in the production, transport, and storage of heat energy, electrical energy, or radioactive
wastes. Also included are systems and components that monitor, control, protect, or otherwise
support the above equipment.
project FME plan A plan detailing specific FME controls for a major or complex activity.
Project FME plans are typically written documents but can also be captured electronically (for
example, as in the work control system). A project FME plan should be formulated as early as
possible to allow for potential changes to the design and planning for the work activity. A project
FME plan typically contains both engineered FME controls as well as passive FME controls.
Passive controls may include signs, barriers, ropes, etc.
reconcile To ensure that the FMEA log accurately lists the items in the FMEA.
responsible lead person The person in charge of and primarily accountable for the work
activity being performed.
self-monitor An individual authorized by the appropriate personnel to control their own access
to an FMEA 1 when no FME monitor is stationed there.
small openings Pipe diameter or component openings greater than 1/2" (13 mm) and up to 1"
(25.4 mm) and oriented in a position facing upward from horizontal or pipe diameter/component
openings greater than 1" (25.4 mm) and up to 2" (51 mm) in diameter in any other orientation.
stop work order The authority to temporarily interrupt a work activity to resolve a concern,
for example, related to FME.
stored items Material kept in a locked cabinet in the FMEA (for example, special tools).
temper film Thin discoloration resulting from heat applied to the surface of a metal, usually
from heat treatment, welding, grinding, flame cutting, or manufacturing heating processes.

D-6
temporary cover An item, which should meet the following requirements, that is used for
sealing and protecting a system or component from the introduction of foreign material when the
system or component is unattended:
Is fire resistant or fire retardant
Is non-brittle, non-splitting, non-melting, and thick enough to avoid damage to
underlying surfaces
Will not damage system or components
Will not deteriorate or decompose over time
Does not cause any chemical reaction
Has a fail-safe design
Is easily detectable and retrievable
D.2.2 Categorization of FME Areas
In some cases, it may be beneficial to designate and categorize areas based on the rigor of the
controls deemed necessary or the impact that foreign materials could have on system operation
and reliability. Common FME area designations are as follows:
FMEA 1 An area where the highest level of FME controls is necessary to protect the station
and personnel against major consequences resulting from foreign material intrusion. Areas
classified as housekeeping zones I, II, or III are typically controlled as an FMEA 1. This includes
the spent fuel pool, reactor containment building emergency sumps, new fuel vault (when fuel is
present), and reactor cavity (when the reactor head is removed).
FMEA 2 An area where less stringent FME controls can be used to protect the station and
personnel against the consequences resulting from foreign material intrusion. FMEA 2 controls
typically consist of using good work practices that minimize the potential for foreign material
intrusion and performing thorough close-out inspections to ensure that no foreign material is left
within systems and components after task completion.
D.2.3 Categorization of FME Events
In some cases, it may be beneficial to designate and categorizebased on a number of factors
events resulting from FME. Common FME event designations are as follows:
Level 1 FME event A condition involving or resulting from inadequate implementation of
FME program controls that results in major actual or imminent consequences to the station.
Level 1 FME events include actual cases of foreign material intrusion resulting in:
a. Lost-time accidents or restricted duty injuries
b. Nuclear fuel cladding failure
c. Reduced main generator output

D-7
d. Inoperable safety-related equipment
e. Non-functional reliability-significant or safety-significant equipment
f. Major damage to reliability-significant or safety-significant equipment, necessitating
extensive repairs or replacement
g. Extensions to the duration of an outage
h. Expenditure of major resources for recovery
i. Nonretrievable foreign material that has a high probability of resulting in a major
consequence to the station (for example, items af above), as determined by an
engineering evaluation
FME program controls that results in minor actual or imminent consequences to the station.
Level 2 FME events include actual cases of foreign material intrusion resulting in:
a. First aid being required or recordable personnel injuries
b. Minor damage to reliability-significant or safety-significant equipment
c. Damaged and/or nonfunctional low- or non-risk-significant equipment
d. Noteworthy delays in task completion
e. Expenditure of noteworthy resources for recovery
f. Nonretrievable foreign material that could result in minor consequences to the station (for
example, items ac above), as determined by an engineering evaluation
FME program controls that proved to be nonconsequential. Examples of Level 3 FME events
include:
a. Nonconsequential intrusion events (for example, did not damage or inhibit component
operation; did not create noteworthy delays in task completion; did not require
noteworthy resources to retrieve; poses no risk if not retrieved)
b. Unsecured items inside an FMEA boundary, but external to a breach or open-air system
(for example, the spent fuel pool, the reactor cavity area during refueling)
c. Material found adrift in the reactor containment building after containment integrity has
been established, but in insufficient quantity to affect emergency sump operability
d. Failure to implement required FME controls/good work practices in the field, shop, or
material storage areas
e. Log-keeping discrepancies

D-8
D.3 Plant/Station Responsibilities
The purpose of this section of the appendix is to provide a listing of common responsibilities
assigned to plant or station personnel associated with supporting and/or implementing the FME
program. These responsibilities may vary, depending on site organizational structure and site-
specific procedures.
D.3.1 FME Responsibilities for All Personnel
The following responsibilities should be applicable to all site and station personnel regarding
FME:
Implement the FME program requirements, and use good work practices that minimize the
potential for the intrusion of foreign material into plant systems and components.
Adhere to all FMEA postings and boundaries.
Do not disturb or remove FME covers and internal barriers without the authorization of the
individuals responsible for the cover, unless an emergency necessitates.
Stop work and notify a supervision if a loss of FME control occurs or is likely to occur.
Maintain a clean work environment that reflects station core work practices.
Reinforce FME program requirements and the use of good FME work practices with peers
and supplementary personnel.
Provide feedback via approved means (for example, lessons learned database, condition
reporting process) to improve the FME program and associated work practices.
D.3.2 Typical Individual FME Responsibilities
The following individual responsibilities are typical for site and station personnel regarding FME
programmatic controls. They may vary depending on site organizational structure and site-
specific procedures.
D.3.2.1 Plant Manager
The most important responsibility of the plant manager regarding FME is fostering a culture that
focuses on the prevention of foreign material introduction into plant systems. Other plant
manager responsibilities relating to FME are:
Fosters a focus on prevention mindset among station personnel regarding FME
Establishes and communicates FME program requirements that encompass all activities
directly related to and associated with plant systems and components

D-9
Holds individuals accountable to high standards of conduct in regard to adherence to FME
program requirements and good FME work practices
Ensures that mechanisms are in place to monitor the effectiveness of the FME program
D.3.2.2 FME Program Management Sponsor
An FME program management sponsor has these responsibilities relating to FME:
Ensures that the FME program is in line with industry standards
Ensures that FME program issues and trends are communicated to the management team
and/or station personnel
Assesses the effectiveness of the FME program
Appoints an FME coordinator
D.3.2.3 FME Coordinator
An FME coordinator has these responsibilities relating to FME:
Communicates FME program issues to the FME program management sponsor, including
observations and trends of FME-related condition reports
Serves as the internal and external point of contact for FME program issues
Identifies FME program improvements via benchmarking activities and/or participation in
industry working groups
D.3.2.4 FME Monitor/Self-Monitor
An FME monitor has these responsibilities relating to FME:
Ensures that he/she is qualified to serve as an FME monitor (FMEM) prior to assuming
duties
Inspects personnel, tools, and materials entering an FMEA 1 to ensure that access
requirements are met
Inspects personnel, tools, and materials leaving an FMEA 1 to ensure that unsecured
materials have not been inadvertently left within the system/component or in the vicinity of
breaches
Ensures that FME logs are properly maintained and that any log-keeping discrepancies are
resolved
Informs appropriate supervisory personnel if a loss of FME control occurs or is considered
likely to occur

D-10
D.3.2.5 FME Area Owner
An FME area owner has these responsibilities relating to FME:
Monitors responsible area(s) on a periodic basis to ensure compliance with the FME program
Coaches and provides positive reinforcement as appropriate
Implements a recovery plan to resume work after loss of FMEA control
D.3.2.6 Department Manager and/or Maintenance Manager
A department manager and/or maintenance manager has these responsibilities relating to FME:
Implements the FME program
Ensures that station and supplemental personnel receive appropriate training on FME
program requirements
Ensures that the causes of consequential FME-related events are identified
Ensures that appropriate corrective actions are implemented when FME program violations
occur or weaknesses are identified
Conducts periodic work site observations to monitor compliance with FME program
requirements and utilization of good FME work practices
D.3.2.7 Maintenance Work Supervisor
A maintenance work supervisor has these responsibilities relating to FME:
Identifies appropriate FME controls for work activities
Conducts pre-job briefings as appropriate that address FME program requirements and work
practices that will minimize the potential for intrusion
Ensures that inspections are performed to identify the presence of foreign material upon
initially breaching a system and prior to final close out
Determines whether personnel may self-monitor while accessing an FMEA 1, based upon the
job scope and whether the individual is a qualified FMEM
Assigns a qualified FMEM to control access to an FMEA 1 if personnel accessing the area
will not self-monitor
Conducts job site observations to monitor compliance with FME program requirements and
utilization of good FME work practices
Ensures that FME log-keeping discrepancies are resolved
Ensures that condition reports are generated when a loss of FME control occurs

D-11
D.3.2.8 Work Planning
A work planning group has these responsibilities relating to FME:
Analyzes feedback to improve future FME controls in work packages
Considers the availability of FME materials that may be needed to accomplish the task
D.3.2.9 Engineering
An engineering group has these responsibilities relating to FME:
Evaluates the individual and cumulative effect of foreign material not retrieved from systems
or components
Provides assistance in determining the removal methods for foreign material not easily
retrieved
D.3.2.10 Training
A training group has these responsibilities relating to FME:
Reinforces the use of FME practices in the classroom and laboratories
D.4 Establishing and Implementing FME Program Requirements
D.4.1 Introduction
The requirements for foreign material controls are most often based on commercial risk factors,
which are the potential for material intrusion, the ease of identification and removal, and the
potential consequences from foreign material left in the system. Generally, tighter controls are
imposed on work situations that involve greater risks.
As noted in Figure D-1, foreign material exclusion should be considered in the work planning
process. Maintenance work request planning should consider:
The potential for foreign material introduction as a result of the work
Work practices to minimize the potential for foreign material intrusion
Cleaning and flushing requirements
Modifications and special procedures should also take into account foreign material exclusion in
the implementing instructions as applicable.

D-12

Figure D-1
Foreign Material Exclusion Flowchart
Courtesy of Exelon
Tools and equipment used inside an FME boundary should be inspected for loose or missing
parts prior to entry and again upon removal. Tool inspections should consider the potential for
the generation of loose parts during use, such as mushroomed heads on cold chisels. If practical,
the same person should perform the entry and removal inspections. As a minimum, someone
familiar with the tool or equipment must perform the inspections
A pre-job briefing should typically be held prior to work in an FMEA and should include the
FME controls applicable to the area. Repeat briefings should be at the discretion of the plant
personnel, based on the need to reinforce the controls or to brief additional personnel.
The loss of control of foreign material inside an FME boundary should be reported immediately
to the responsible supervisor. Loss of control has occurred when the established barriers to
foreign material intrusion have failed or are suspected to have failed. Examples include log
discrepancies that cannot be immediately resolved, material items that cannot be accounted for,
observed foreign material in an unexpected location, or other abnormal conditions involving
foreign material.

D-13
Loose clear-plastic items, unless marked or colored so that they can be seen in a wet or dry
system, should not be allowed in the FMEA. When practical, temporary covers should be
installed over system or equipment openings during periods when no work is being performed to
prevent foreign material intrusion.
D.4.2 General Programmatic Guidance
The FME program focus should be to use common sense methods to prevent foreign material
from entering plant systems. Responsible workers should be the first line of defense to avoid
events that could affect the safety and operability of the plant.
Habitability, safety, radiation, security, equipment, and system requirements should be
considered when establishing FME controls. However, some routine maintenance activities are
typically exempt from FME controls, provided that cleanliness and normal good worker
practices are observed in accordance with station procedures. Routine activities exempted from
FME controls may include, but are not limited to, the following:
Visual inspections of equipment, tag out of equipment
Operation of breakers
Opening cabinets or panels
Draining, filling, and venting of systems (small openings only)
Valve repacking
Traveling screen maintenance
Opening of cable tray covers or junction boxes
Obtaining samples
Testing or calibration of instrumentation that does not require a system breach
The FME control program should ensure that personnel restore and verify system cleanliness
following work. This may range from a simple visual inspection to a complete system flush.
Similarly, plant personnel should follow plant procedures to ensure that cleanliness requirements
are met for the system being worked.
The FME program should encourage the use of FME briefings. The supervisor or designee
should brief personnel on appropriate FME job controls, considering the need for FME materials
such as pipe plugs, covers, and caps that may be needed to accomplish the task.
D.4.3 Sources of Foreign Material Contamination
The FME control program should communicate to maintenance personnel common
contaminants, which often include, but are not limited to, the following:
Welding and gas cutting debris
Metal chips, shavings, and filings created by machining and repair operations

D-14
Corrosion
Materials used for cleaning
Improper lubricants
Dirt, fly ash, coal dust
Contaminants found on shoes and clothing
Pens, rulers, coins, keys, and other typical contents of a shirt pocket.
Tools
Trash
The FME control program should also describe typical activities that produce foreign material,
such as:
Drilling, cutting, grinding, machining, filing, and lapping
Welding or thermal cutting activities
Lubricants or cutting oils
Use of tape, plugs, or seals that may leave a residue
Sandblasting
Sweeping or using air or water to clean
Any activity including equipment inspection and testing that requires opening a normally
sealed component
D.4.4 Defining the Scope of Equipment Controlled by FME Procedures
The FME control program should define the scope of equipment that will be controlled by FME
procedures. Maintenance personnel, as well as contractors, should follow FME practices,
particularly on systems and components that are critical to the power plant such as feedwater,
condensate, steam, lubricating oil, turbine, and generator. These systems are likely to suffer
component damage if contaminated by foreign material.
The following list provides examples of critical components that should be included in the scope
of a typical FME control program:
All lube oil reservoirs
All piping systems
Boiler tubes, headers, and drums
Bulk storage tanks
Compressed air systems
Condensers

D-15
Electrical cabinets
Feedwater heaters
Flash tanks
Generators and seal oil systems
In-line flow elements
Large electric motors
Pumps
Switchgear
Transformers
Turbine shells and piping
D.4.5 Training and Qualification of Individuals
The FME control program should define training requirements for site and station personnel as
well as contractors. Training on FME should minimally be provided to independent contractor
personnel as required. The first line supervisor may permit trainees or short-term employees to
work under the direct supervision of qualified personnel. The qualified individual should then
ensure that appropriate FME controls are maintained.
A general knowledge of FME should be provided to personnel who have access to work areas.
Group-specific training can be a useful tool for areas such as the refuel floor, turbine, or primary
containment. These groups often encounter special FME needs.
Interactive learning modules and mockups are a popular and practical way to coach and
positively reinforce FME expectations. Continuing training maintains and enhances performance
levels; consequently, continuing training topics such as the following should be considered:
Observed weaknesses
Operating experience
Lessons learned from outage critiques
Training for infrequent or difficult tasks
Refresher training
Reinforcement of management expectations

D-16
D.5 Developing and Implementing FME Control Plans
Project coordinators should develop and implement FME control plans in support of major work
activities or projects for which the likelihood and potential consequences of foreign material
intrusion are moderate to high (for example, refueling, main generator repair activities). FME
plans should be communicated to project participants in advance of project commencement and
at appropriate times during the project.
D.5.1 Factors to Consider When Developing an FME Control Plan
Some factors to consider when developing a plan to control FME are as follows:
Defining roles and responsibilities Designate an appropriate individual to be responsible for
reviewing and implementing the FMEA requirements, initiating corrective actions, and
verifying system and component cleanliness prior to closure. Identify an individual with in-
depth system knowledge who is the best point of contact for the development of an FME
retrieval plan if applicable.
Job duration Jobs lasting more than one shift might suffer lapses in control due to
omissions in turnovers or poor communication.
Work scope The FME control plan should contain a description of the major FMEA work
activities, including area setup and foreign material generation. Additionally, it should
include a description of support activities, such as scaffold erection and dismantling, tool
decontamination, foreign material generation, and waste collection.
Area rating Areas rated high or moderate may require more planning to achieve the desired
control than would be usual in a pre-job briefing.
Access control A detailed description of the pre-work activities required to establish the
FMEA might be as simple as establishing the area boundaries, or it might include fabrication
or erection of enclosures. The plan should include a description of the boundaries, the point
where the FME log will be maintained, and where the FME monitor will be stationed.
FME control Measures to ensure exclusion of foreign material should be included. If
applicable, describe measures to be taken as conditions change or if new issues arise. Areas
requiring continued support from other groups, large quantities of tools, local FME tools,
special prefabrication, or construction may require a plan to minimize delays. Detailed
descriptions of the tools required to perform the work activities should include the number of
tools, how the tools will be made fail safe, transportation of tools within the FMEA, and
where the tools will be available. The use of non-fail-safe tools and an FME monitor, if
applicable, should also be described in this section of the plan. If applicable, include plant or
industry foreign material experience for the activity, system, or component.
Immediate actions This plan describes actions that should be taken for foreign material
intrusion and removal. This should include stopping work and who to contact before
attempting to retrieve or remove the foreign material.
Control plan approval The first line supervisor should approve control plans required by the
plant or site FMEA categorization.

D-17
D.5.2 Typical Contents of an FME Control Plan
FME plans should typically include the following information:
Work scope
Activities within the work scope that warrant FME controls, based upon the probability of
foreign material intrusion, the difficulty involved in detecting and/or retrieving any foreign
material introduced, and the potential consequences to the plant or personnel if intrusion
occurs
Location, arrangement, and construction of FMEA boundaries
When FMEAs will be established (for example, prior to breaches)
Personnel and material access requirements, log-keeping requirements
Specific FME controls and work practices that will be used to minimize the potential for
foreign material intrusion (for example, removing major components for disassembly outside
FMEA, use of temporary FME devices, etc.)
Applicable lessons learned and operating experience
Contingency plans in the event that foreign material intrusion occurs
Activities that will be exempt from FME controls and the basis for their exemption
FME close-out inspection/flushing requirements

D-18
Figure D-2 illustrates an example of how to document an FME plan.

Figure D-2
Example of an FME Plan Document
Courtesy of Progress Energy

D-19
D.5.3 Establishing the FMEA
The responsible supervisor should establish the FMEA boundary based on the potential for
foreign material introduction. Potential foreign material that will remain in the FMEA should be
inventoried and accounted for. The FMEA boundary should be as small as practical and should
use physical barriers such as walls and equipment, where possible, with the remainder designated
with FMEA barrier tape. The installation of temporary physical barriers or a clean enclosure
should be considered if there is a strong potential for the introduction of dirt, debris, or other
foreign material from adjacent areas. The use of special clothing, securing of ventilation systems,
stopping adjacent work, or similar controls may also be required.
FMEA barrier tape should be used, if available, to designate the FMEA boundary. If FMEA
barrier tape is not available, an alternative tape can be used, or a permanent boundary can be
marked. If an alternative tape is used, an FMEA boundary sign approximately 8 1/2 x 11" (21.6 x
27.9 cm) should be securely attached every 45' (1.21.5 m). Additional devices including pipes
covers, duct tape, and polyethylene plastic film can also be used as boundary protection. The
FMEA should have the applicable signs and attachments stationed as needed, and these may
include a personnel log, material log, and responsibility sheet. Figures D-3 and D-4 are examples
of typical FME boundary signs.

Figure D-3
Example of an FME Boundary Sign

D-20

Figure D-4
Example of an FME Boundary Sign
Courtesy of Ontario Power Group
D.5.4 Determining Appropriate FME Controls for the Area
Prior to performance of work activities, the supervisor should identify if FME controls are
necessary, as well as the level of FME controls needed (for example, FMEA 1 or FMEA 2), if
applicable. In some cases, a decision tree may be helpful to aid the supervisor in making this
determination, which is based upon the following considerations:
Whether the work will be performed in a housekeeping zone I, II, or III area, as specified in
plant housekeeping procedures (if applicable)
The potential for foreign material intrusion during the activity
The difficulty involved in detecting and/or retrieving any foreign material introduced
The potential consequences if foreign material enters a system or component and is not
retrieved.
When determining whether FME controls are necessary for a given task, the supervisor should
also consider the potential for loose material associated with the task to enter unrelated
equipment in the vicinity of the work. For example, the supervisor of a debris-producing activity
such as grinding would need to consider the potential for debris to enter an adjacent motor
through its casing vents, as well as any open vent valves in the vicinity. The use of tents, shelters,
or drapes may be necessary if the task (for example, spray painting, drilling, grinding, insulating,
or chemical cleaning) could generate airborne debris or corrosive fumes that could be introduced
into systems or nuclear fuel storage areas.

D-21
If an activity will be performed within an FMEA 1, the supervisor should determine whether
personnel may self-monitor when accessing the area. Self-monitoring is typically reserved for
non-intrusive activities such as routine tours, inspections, job walkdowns, and surveillance test
performance.
D.5.5 Establishing an FMEA Boundary
An FMEA boundary should be erected prior to performing tasks requiring FMEA 1 controls. For
tasks afforded FMEA 2 controls, use of an FMEA boundary is typically at the discretion of the
job supervisor. Figure D-5 illustrates examples of denoting an FMEA boundary and establishing
entry locations.

Figure D-5
Examples of FME Boundaries and Entry Locations
Prior to establishing an FMEA boundary, workers should remove non-essential materials and
debris from the area that will be enclosed by the boundary, including overhead areas.
Emergency personnel (for example, medical first responders or fire brigade personnel) and their
equipment should have unhindered access to an FMEA during emergency situations.
D.5.6 Installing the FMEA Boundary
The FMEA boundary should be installed in accordance with plant and site procedures, taking
into consideration the following guidance. The supervisor should ensure that the boundary is
configured (for example, proper materials of construction, adequate dimensions) so that it

D-22
provides adequate protection against intrusion of foreign material. If the area is large enough,
then consideration may be given to having multiple access points. The job supervisor should
ensure that one or more qualified FME monitors are stationed to control access to an FMEA 1,
unless self-monitoring will be performed.
Barriers are used as appropriate to designate the FMEA boundary. Temporary covers can be used
as an FMEA boundary. To improve visibility, FME barrier decals can be used. Signs are
recommended for large boundaries, but to improve visibility, FMEA boundary signs can be used
in addition to the FMEA sign. Another option to improve visibility is the use of FMEA boundary
tape.
D.5.7 Conducting Pre-Job Briefings
For any task having the potential to result in a Level 1 FME event, the job supervisor should
perform a pre-job briefing that includes an overview of the FME plan. Specifically, the pre-job
briefing may also include discussion of any FME controls for the task, the potential
consequences of foreign material intrusion, and contingencies in the event that intrusion occurs.
All personnel entering an FME area must be advised and an appropriate sign placed into or
adjacent to the FME area stating that any inadvertent loss of tools, instruments, materials, and/or
personal belongings inside the FME zone must be reported immediately.
D.6 Performance of Work Inside the FMEA
D.6.1 FMEA Entry Requirements
Workers should ensure that the following activities are completed prior to commencing work in
the vicinity of a breach and/or crossing an FMEA boundary:
Fasten badges and dosimeters securely to the clothing. If tape is used to secure these items,
do not tape over the audible or visual part of the dosimeter.
Remove loose items on the person, including removable jewelry (for example, wristwatches,
necklaces, earrings), and place them in a secure area or inside taped pockets.
Verify that pockets are empty or taped closed.
Use a container with a fail-safe lid for items that are too small or numerous to attach lanyards
or other control devices. Contents within a container should be inventoried before taking the
container into the FMEA.
Fasten eyeglasses to the wearer with tape, nylon cord, or eyeglass retainer straps if the
possibility exists of the glasses being introduced into the system.
Inspect all tools and materials that will be used in the vicinity of a breach for loose or missing
parts. Record missing parts in the work document (or individual entry log), if utilized.

D-23
If accessing an FMEA 1, workers should complete the following additional activities prior to
entry:
Tape over zipper tabs and buttons if the possibility exists of their being introduced into the
system as foreign material.
Determine whether tools are fail safe prior to their being transported across the FMEA
boundary. If the tools are not fail safe, ensure that lanyards are attached that will be capable
of preventing the loss of the tool.
Ensure that no black matting-like material is allowed in the FME 1 area without being tagged
and tied off.
D.6.2 Use of Control Logs
Control logs should contain enough information to ensure accountability of tools and equipment.
Items with missing parts or damage could result in questionable accountability. Control logs
should be considered for critical or large jobs, and typically, the following FME areas require
control logs:
Spent fuel pool
Torus
Reactor cavity with the head removed
Turbine with covers removed
If logging is required, tools, equipment, and material released from the hand and not to be
permanently installed should be logged prior to entry into the FMEA. Items specifically
controlled by procedures (electrical jumpers) and personal items (eyeglasses, dosimeters, hard
hats, etc.) typically do not require logging. Reactor head and internals, blade guides, new nuclear
fuel, and any other large item that would be conspicuous by its absence, likewise, typically
would not require logging.
Special precautions should be taken to track cloths, plastic bags, tape, tools, covers, and missing
parts of tools and equipment. In this regard, the following precautions should be considered:
Cloths (cleaning/wiping) should be logged by size and quantity (for example, wiping cloth -
large - Qty. 6).
Plastic bags should be logged by size, color, and quantity (for example, plastic bags - yellow
- 6" x 18" - Qty. 4).
Bulk quantities of tape (for example, full or partial roll) should be logged.
Each tool should be logged separately. Tool boxes should be inventoried.
FME pipe covers or plugs should be logged.
Missing parts or damage to tools and equipment should also be noted to ensure
accountability.

D-24
The FME monitor/self-monitor should log all personnel and materials (for example, tools,
supplies, test equipment) entering and exiting the FMEA 1 on the appropriate datasheet. Material
that is inherently fail safe can be exempt from logging requirements. Each logged item should
indicate a name and badge number denoting who is responsible for the material. Any non-fail-
safe items that will remain within the boundary for an FMEA 1 area should be logged on a
datasheet (that is, an individual entry log).
Figure D-6 illustrates an example of an individual entry log.

Figure D-6
Example of an Individual Entry Log
Courtesy of South Texas Project
If items remaining inside the FMEA 1 are expected to remain inside the area for an extended
period, the FME monitor/self-monitor may elect to log the items on a long-term placement log
instead.

D-25
Figure D-7 illustrates an example of a long-term placement log.

Figure D-7
Example of a Long-Term Placement Log
Courtesy of South Texas Project
Electronic logs may be used to record items within an FMEA 1, in lieu of datasheets.
It is recommended that control logs be reconciled each shift while the FMEA is active; long-term
tasks should be reconciled at least once every seven days. The log should also be reconciled just
prior to job closure. Infrequently accessed permanent FMEA logs should be reconciled
periodically.
D.6.3 Monitoring the FMEA
Monitors are typically used for jobs with high FMEA classifications, but they should also be
considered for critical or large jobs. The FMEA monitor should establish and maintain
housekeeping requirements suitable for the classification of the FMEA. They should also ensure
that items not required for performance of the assigned work activity are kept outside the FMEA.
An FMEA monitor should ensure that loose objects such as badges, glasses, and dosimetry
devices are secured to prevent their entry into a breached system or component. They should
understand and ensure that the FMEA requirements are met, and they should observe and correct
poor FME habits of personnel within the area. The monitor may deny FMEA entry to individuals
not associated with the work task or may stop work to ensure FME program compliance. The

D-26
monitor should directly observe work activities, recognizing that complex tasks or large jobs
may require additional FME monitors for assistance. Finally, the FMEA monitor should maintain
and reconcile applicable logs.
An FME monitor may control access to more than one entry point from a single station, provided
that he/she is positioned in a location that facilitates effective implementation of access control
requirements at each entry point. An FME monitor may perform other duties at the discretion of
the job supervisor, as long as the proper control of access to the FMEA is not compromised.
Establishment of the FMEA boundary should be recorded in the work document.
D.6.4 Cleanliness and Readiness Inspections
The FME lead, in concert with engineering, should conduct a cleanliness and readiness
inspection prior to commencing FME operations and maintenance activities inside the FMEA.
The following activities should be considered at this time:
Typically, the FME area should be cleaned and left in a broom-clean workman-like manner.
The FME lead should be allotted approximately 30 minutes to inspect the FME area and
ensure that all items that have been introduced are listed on the inventory sheet for that area.
The FME engineer should ensure that a complete inventory of scaffold material, etc., has
been completed and given to the FME technician at the entrance to the FME area.
The FME lead should post Do Not Enter Signs only on the exterior of emergency exit
doors and add signs with the name of the individual to contact if someone needs to enter
through the posted area.
The FME lead should inspect the area, ensure that a complete inventory of all materials for
the work activity has been accomplished, and advise the FME engineer when they are ready
to commence FME operations for that area.
D.6.5 Performance of Maintenance Activities Within the FMEA
Personnel entering an FMEA should appropriately display their security badge and secure it to
their clothing by at least two independent means. Taping of the security badge is allowed if the
wearer deems it necessary. Jewelry (except wedding rings), watches, and wallets should have
already been removed and secured before entering an FME area.
All personnel entering the FME zone must be authorized in writing. All material that enters the
FME area must be logged in, and it must be logged out when the final close-out audit is
performed. All material that enters or leaves the FME area, including the rigging on a crane
hook, must be accounted for.
Any tools or equipment to be retained in a work area longer than the end of daily work shift
should be considered long term, placed on the long-term placement log, and given a tag by the
FME monitor. Materials to be maintained beyond one shift are designated as long-term materials
and must be approved by the craft lead supervisor responsible for the equipment within the

D-27
FMEA. This approval authority should not be delegated to any other individual. These materials
should be given a numbered tag and accounted for separately in a long-term logbook. Craft
toolboxes and tools are not considered long-term material and will be logged into and out of the
FMEA.
Workers should inspect the work area and remove potential sources of foreign material prior to
initially breaching systems, components, or electrical equipment, and prior to removing
temporary FME devices during work performance. Inspections should pay particular attention to
overhead areas.
If any materials that are brought into FME area must be subdivided, the respective craft foreman
must approve the subdivision, and the FME monitor must be notified prior to their subdivision
within that FME area. Subdivision of materials inside an FME area must be avoided if at all
possible. If subdivision can not be avoided, each piece must be individually tagged after
subdivision and identified within the long-term logbook.
It is typically the responsibility of the person authorizing the initial access into the FME zone to
ensure that the person requesting entry into the FMEA has signed the appropriate documentation
and understands the rules for entry into the FMEA. He/she should authorize entry into the FMEA
after they have determined that the person requesting entry has full knowledge of the FMEA
rules.
Upon breaching a system, component, or electrical equipment, workers should perform an initial
inspection for any foreign material already present (for example, dirt, loose fasteners, etc.).
Foreign material found within or entering a system during task performance that is determined to
be immediately retrievable should be promptly removed from the system or component.
Workers and/or FME monitors/self-monitors should inform the job supervisor personnel
whenever a loss of FME control has occurred or is considered likely to occur. Additional
guidance is provided in Section D.7 of this appendix.
Workers should ensure that breaches are covered when unattended and whenever work is not
actively in progress. FME devices, as described in Section D.6.9 of this appendix, may be used
for this purpose; however, reinstalling access panels or closing cabinet doors may be more
appropriate in certain cases. Prior to final closure of a breach, the job supervisor should ensure
that appropriate personnel perform a thorough inspection to verify that no foreign material is
present.
When all breaches have been closed (for example, components reinstalled in the system, access
covers reinstalled, panel doors closed), FME controls can be relaxed. The job supervisor should
ensure that logs used to control work within the FMEA are completed with all discrepancies
resolved. The job supervisor should ensure that the following records are included in the work
package or transmitted separately for record retention:
Datasheet (individual entry log)
Long-term placement log
Printed copies of electronic logs

D-28
D.6.6 Examples of Good Work Practices Inside the FMEA
The following section describes a number of good work practices that should be implemented
when performing maintenance activities inside an FMEA. The list is not all inclusive, and the
examples are provided for illustrative purposes only. Users of this report should recognize that
not all of the examples may be applicable to a given work order.
Cover all unattended openings into components.
Clean dirt, coal, fly ash, or any other form of debris from around covers, caps, and other
devices before opening them for inspection or servicing.
When opening critical components, ensure that areas above these components are clean so
that no debris will drop into openings of these components. If work will be done overhead
while the component is open, cover the open component with tarps or other covering to
prevent debris that is dislodged or dropped from entering the component.
Ensure that welding electrodes, stubs, and broken flux coating material is removed from
components.
Clean the work area before beginning work; this may include washing down or vacuuming
the area.
Orient work so that debris will not drop into components.
Cover openings on the main turbine, generator, hot well pumps, boiler circulating pumps,
high-pressure boiler feed pumps, etc., during maintenance activities.
Ensure that all piping and tubing are free of foreign material before and after installation.
Do not introduce material that may produce corrosion into components.
Perform shot- and sandblasting only in areas that can be adequately cleaned.
Use only approved solvents for cleaning.
Use only approved lubricants.
Use only approved tapes, plugs, or seals. Some tapes may leave residue (adhesive) that can
cause damage.
Use approved procedures when flushing systems.
Do not allow personal items such as jewelry, change, pens, and so on into the FMEA. No
material should be allowed in the FMEA unless it is absolutely necessary.
Secure all tools, safety glasses, badges, gloves, and other loose items with lanyards, tape, or
other devices.
Stage tools, parts, and materials outside the FMEA. Remove all packaging and other
unnecessary material before entering the FMEA.
Inspect tools for parts that might come off during use. Look for items such as loose handles,
splintered wood parts, and loose wire brush bristles. Clean all tools, materials, and parts
before entering the FMEA.

D-29
Limit the use of clear materials, such as face-shield visors, in the FMEA. They will be
difficult to see if they are misplaced. Clear materials should not be used near the spent fuel
pool (that is, inside the handrails around the spent fuel pool, the new fuel storage vault, the
cask handling vaults, and the fuel handling tool lay-down area). Likewise, do not use clear
materials inside the reactor cavity (that is, inside the handrails around the reactor cavity, the
lower internals storage area, and the in-containment storage area) due to the inherent
difficulty in identifying their presence. Authorized exceptions to this requirement typically
include:
The clear plastic float used to improve water visibility for fuel handling operations,
provided it is secured with a lanyard.
Items that have been permanently marked so that they are clearly distinguishable in water
(for example, a face shield with a black mark around the perimeter).
Use vacuum or exhaust systems to remove any generated airborne debris from painting,
blasting, grinding, etc.
When cutting wires, control the ends that are snipped off.
Control all metal debris (screws, connectors, wire strippings, etc.) in all electrical enclosures.
Account for all rags, cushions, cardboard, and other miscellaneous items that are used in an
FME area.
Do not use excessive amounts of lubricants; the excess may collect dirt, ash, and other debris.
Follow approved welding practices for the removal of tubes and piping.
Ensure that all open pipes, tubes, or systems, 30" (76.2 cm) or less in diameter, regardless of
whether they are new, to be re-used, or to be removed, have FME covers in place. This
applies to material lying on the floor, hanging in place, or staged in racks, store rooms, or
lay-down areas. The only exception is when the tube or pipe is completely disconnected from
the system and color coded with bright orange or pink paint to indicate that it is scrap.
On vertical runs of tube or pipe, make the first cut at the bottom using an abrasive cutoff
wheel or other nonthermal means. Insert a piece of sheet metal into the kerf created. The
upper cut can then be made using a thermal method.
Perform maintenance activities in a manner that reduces the possibility of introducing foreign
material into a system or component.
Create no situations that cause a loss of a shutdown safety function.
When working in electrical enclosures with multiple doors or access openings, open
only those doors or access areas required to perform the task.
Use caution when opening and working in control cabinets, relay cabinets, or junction
boxes to ensure that tools, parts, dirt, debris, or filings do not fall into electrical
equipment.
Ensure that metal shavings or debris does not enter plant systems or electronic
components during drilling activities.

D-30
Ensure that the system or component in the field is protected to prevent entry of
foreign material during removal of plant equipment for repair or bench calibration.
Ensure that FME practices are maintained while working on equipment in shop areas.
Items awaiting maintenance should be protected for FME purposes with appropriate
covers.
When adding or filling oil reservoirs, do not leave the filler cap or sight glass off
when unattended.
Secure materials while transporting within the FMEA to the extent practical.
Do not use tie wraps with metal tabs in areas where dislodged tabs could come into contact
with primary systems or nuclear fuel.
Do not use clear plastic around water-filled pools or cavities, for example, the spent-fuel
pool, reactor cavity, or sumps when flooded.
Use visible colors for plastic and tape to the extent practical.
Use supplied FME covers to reduce waste volume.
Minimize the use of wire brushes because wire bristles fall out easily and will damage fuel if
left in primary systems.
D.6.7 Implementing Graded FME Controls
Major work activities on critical pieces of main turbine deck equipment pose opportunities to
introduce unwanted foreign material into the equipment. This foreign material can challenge the
reliable and safe operation of these critical pieces of equipment. To proactively reduce this threat
of foreign material introduction, FME controls are exercised during critical equipment
maintenance activities.
To ensure that there is consistency in the application of these controls, the following guidance is
provided to implement a graded FME program on the turbine deck.
D.6.7.1 Implementing FME-2 Controls
These controls should be implemented through personal heightened awareness of the
opportunities to introduce unwanted foreign material and the consequences of doing so. The
controls include minimizing small loose items taken into the area, tethering tools and other
equipment that could fall into the space with lanyards, taping pockets that contain small loose
items, ensuring that badges are secured by two independent means, etc.
Examples of when FME-2 controls should be implemented on the turbine deck include the
following:
Removal of manways on the main turbine outer cylinder covers
Removal of manways on the moisture separator reheater shell side or hemi-heads

D-31
Removal of the governor or throttle valves on the high-pressure turbine
Removal of the low-pressure turbine outer or inner cylinder covers
Removal of the high-pressure turbine upper casing
Opening of the exciter doghouse access doors or removing the exciter doghouse
Removal of the steam generator feed pump turbine (SGFPT) upper casing
Removal of the SGFPT lube oil reservoir cover or the HP/LP governor/stop valves
D.6.7.2 Implementing FME-1 Controls
These controls stringently monitor materials taken into and out of the subject space. The controls
include determining the original condition of the subject space as controls are first implemented,
using trained personnel to log workers and material taken in and out, allowing no loose material
(watches, pens, and other personal items) on the workers, securing the space when work is not
being performed, etc.
Examples of when FME-1 controls should be implemented on the turbine deck include the
following:
Removal of a generator belly manway to permit generator crawlthrough
Removal of any upper manway that permits access into the main generator
Removal of the hydrogen cooler bundles
Removal of a bearing bracket that exposes an opening into the main generator
FME-1 controls may also be conservatively applied when restoring the exciter doghouse back
onto its foundation. Application of FME-1 controls provides additional assurance of exciter
integrity until the doghouse access doors are ready to be closed and locked.
D.6.8 Ensuring Cleanliness Inside the FMEA
D.6.8.1 General Guidance
The FMEA should be kept clean to prevent dirt and foreign objects from entering the turbine-
generator components and systems.
The FMEA will not be used for parts or material storage or to conduct work that is not essential
to outage work for material contained within the FMEA.
The FME monitor station worktable should be kept clear and should be maintained in a clean and
orderly fashion. Personal items are specifically forbidden to be stowed on the FME work table,
but may be stored in specifically designated stowage zones.

D-32
Maintain cleanliness to minimize cleaning after repairs; consider using one or more of the
following methods:
Vacuum components or systems.
Wipe with lint-free cloths, either wet, dry, or tacky, as needed.
Use dams to minimize the spread of dirt and debris in the systems.
D.6.8.2 Cleanliness Control of Existing Systems and Components
This section applies to activities that open existing systems and components. It includes criteria
for closing systems with new components, new portions of systems, and existing components.
Users should recognize that serious personnel injury could occur if a system is opened without
the proper boundary clearance.
D.6.8.2.1 Opening of Existing Systems and Components by the Clean Cut Method
The work package should provide a way to capture fluid that will be released when the opening
is made. Maintenance personnel should remove any loose debris in the vicinity where the cut is
to be made. If a hard-wheel cutter is to be used, remove the cut debris from the surface with a
clean cloth, paper towel, or vacuum cleaner. If the cutting tool to be used is not a hard-wheel
cutter, then perform the cutting operation as follows:
Erect screens, drapes, tents, blankets, and other covers, as required, to protect the
surrounding equipment from debris generated by the cutting process.
Monitor the cutting area for discoloration (overheating), and perform the cutting operation to
reduce as much base metal around the circumference of the pipe as possible without breaking
through the inside diameter.
If indications of overheating are observed, then move the cutting tool to a new location
around the circumference, or suspend the cutting operation until the metal cools.
Remove the cut debris from the surface with a clean cloth, paper towel, or vacuum cleaner.
Break through the inside diameter by mechanical means (for example, a tubing cutter or
chisel). Note that the cleanliness of systems that have been in service will be degraded. The
intent of the following inspection is to detect any unusual conditions.
Perform the opening cleanliness inspection, and record the as-found condition.
If the as-found inspection reveals unusual corrosion, erosion, foreign material, etc., then
submit the as-found inspection results to the responsible supervisor for an evaluation.

D-33
D.6.8.2.2 Opening of Existing Systems and Components
The work package should provide a way to capture fluid that will be released when the opening
is made. Maintenance personnel should perform an opening cleanliness inspection, and record
the as-found conditions. If the as-found inspection reveals unusual corrosion, erosion, foreign
material, etc., then submit the as-found inspection results to the responsible supervisor for an
evaluation.
D.6.8.2.3 Maintenance of Opened System
If an opened system is left unattended for any length of time, then maintenance personnel should
install a cap, covering, etc., over the opening. If protective caps are removed to perform work
and the orientation of the opening is such that foreign material entering the opening would be
inaccessible for removal, then the following requirements should be observed prior to
performing any activities that could generate foreign material:
Secure all items small enough to fit inside the opening with a lanyard or other suitable means
to the user or fixed framework.
Cut and prepare the pipe and components in a position to avoid contamination of crevices,
blind holes, deadlegs, undrainable cavities, and inaccessible areas when possible.
When all work activities that generate foreign material are complete, remove the foreign
material from internal and external surfaces with a clean cloth, paper towel, or vacuum
cleaner.
D.6.9 Use of FME Devices
D.6.9.1 General Guidance
FME devices (for example, covers, internal barriers, and lanyards) should be used in any
situation where they reduce the potential for foreign material intrusion, such as:
Covering open/exposed mechanical and electrical components when they are not being
actively worked on in the field.
Covering equipment (for example, valves, circuit breakers) removed from systems or
switchgear, unless the equipment will be afforded a complete teardown and reassembly.
Covering open components or exposed electrical components when they are not being
actively worked on in the shop and once equipment is ready for reinstallation in the plant.
Covering components stored in the warehouse that cannot be easily verified (that is, with the
naked eye aided only by a flashlight) to be free of foreign material prior to installation in the
plant.
Covering open vent and drain lines more than 1" (25.4 mm) in diameter with a breathable
(for example, mesh screen) FME cover. Consideration should be given to installing a
breathable FME cover on vent lines less than 1" (25.4 mm) in diameter if they are located in
a high traffic area or if maintenance in the vicinity could introduce foreign material.

D-34
D.6.9.2 External Temporary FME Covers
Canvas soft covers, plastic pipe caps, and hard covers are typically used as external FME covers.
Hard covers (for example, aluminum, polyurethane) should be used to cover breaches if soft
covers would not prevent the entry of material that could conceivably impact them. Tape should
not be used as an FME cover; however, it can be used to affix FME covers in place in oil-free
environments. Herculite, Visqueen or equivalent materials can be used to cover openings if
appropriate soft or hard covers are not available, provided that it is securely affixed in place.
Shrink wrap and original material packaging that provides sufficient protection against foreign
material intrusion may be utilized as FME covers while material is in storage. Hoses attached to
vent and drain lines are considered adequate substitutes for breathable FME covers.
Materials utilized as external FME covers should be:
Clean and free of loose debris
Fire resistant/retardant (based upon the intended application)
Made of nonbrittle material
Sturdy enough to prevent entry of material that may impact them
Resistant to melting if used in high-temperature applications
Constructed of materials other than clear plastic
Unlikely to deteriorate or decompose during the period of installation
Highly visible and/or brightly colored to contrast with the item on which they are used
Unlikely to mark or mar the equipment on which it is installed
Unlikely to induce corrosion at the point of contact with hardware
Should not be used to clean up, stockpile, or transport material
Should not damage the adjacent system or component
Should not cause any chemical reaction
Whenever practical, FME caps and covers should be clearly marked as serving that purpose (for
example, annotated FME, FME Barrier, etc.) using permanent markers, stickers, or other means.
FME caps or covers used on vent paths (vent valves, open manways, etc.) on tanks or other
structures that are subject to pressure changes should be capable of permitting venting.
FME caps and covers should be installed in a manner that makes them unlikely to fall into the
system or component during installation or removal. In some cases, it may be necessary to secure
FME caps and covers with a lanyard. Care should be taken when removing FME caps and covers
to prevent entry of foreign material that may have accumulated on or around the cap or cover.
FME covers, when subject to high traffic, abrasion, or other situations that would cause them to
fall off or become damaged (such as condensate or residual water draining out of the tube, pipe
or system), should be made of steel, aluminum, or substantial plastic. For large-diameter

D-35
openings (12" [30.5 cm] or larger), plywood, canvas, or nylon bags should be used. For openings
subject to fire fall, grinding, arc air, or any other thermal operation, steel caps should be used.
Large-diameter FME covers subject to the support of human weight should conform to OSHA
standards.
Staged pipe or conduit typically does not require capping or plugging if stored in a waterproof
area or stored in a manner that will allow water to drain through.
D.6.9.3 Internal Barriers
Internal barriers (for example, inflatable bladders or pipe dams) should possess the same
attributes as external FME covers described in the preceding section. Internal barriers should be
tethered externally whenever possible to increase their visibility and to avoid their inadvertent
loss into the system during work activities. The installation and removal of internal barriers
should be documented in the work package and/or on the FME log sheet, if utilized.
Maintenance personnel should ensure that the system or component is clean prior to removing
the internal barrier to prevent inadvertent introduction of foreign material upon barrier removal.
Caution should be exercised when removing internal barriers because pressure from system in-
leakage may exist and can create a missile hazard. System leakage or draining could also result
in a vacuum being drawn within the system so that FME devices could be inadvertently drawn
into the system when de-tensioned.
Water-soluble paper, if properly utilized, can be used as FME protection during tube or pipe joint
preparation. Sponges can also be used as FME protection during tube or pipe joint operations as
long as a sponge log is maintained and implemented. Water-soluble cones should not be used as
FME prevention during joint preparation.
Dams, plugs, or caps should be secured if they cannot be easily retrieved. Removable tape should
be used instead of adhesives in contact with bare metal surfaces. Paperbacked (masking) tape is
not recommended for use on metallic surfaces.
Caution should be exercised to recognize that certain covers or filters used on ventilation systems
can cause heat dissipation problems. Temporary filters, such as Scott Foam, should be installed
over ventilation louvers and comparable openings on equipment, for example, electric motors,
where heavy particulate matter might be present. Openings that are used for access can be
provided with a clean room attachment, whereby local cleaning within the room will minimize
the possibility of contamination entering through the opening.

D-36
D.6.9.4 Lanyards
D.6.9.4.1 Types and Composition of Lanyards
Lanyards should not be constructed of material that could chip, flake, peel off, or become
dislodged. Each lanyard should be inspected and tested by hand to ensure that they are securely
attached and are strong enough to resist the breaking force that would result when the attached
item is dropped. Using materials that are easily decontaminated decreases the radiological waste
generated. Radiological waste increases the cost of doing business and has a negative impact on
the environment.
Lanyards manufactured from corrosion-resistant steel wire are recommended for applications
involving long-term exposure to harsh environments, such as water containing boric acid or
spent fuel pools. Nylon lanyards should be discarded if they come into contact with boric acid
crystals or borated water. Nylon lanyards should have the ends fused to prevent fraying. Poly
rope has a history of deteriorating and should not be used in a water environment.
D.6.9.4.2 Proper Use of Lanyards
For personnel safety reasons, lanyards should not be used near rotating equipment. Large and
readily retrievable items typically do not require lanyards. Power cords should not be used as
lanyards.
Lanyards should be attached to tools used in an FMEA 1 that are not inherently fail safe.
Lanyards provide a back-up method for preventing the loss of tools or materials. Tools or
materials should not be allowed to dangle so that failure of the lanyard results in the loss of the
tool or material. Lanyards of the shortest practical length should be used to minimize the
dropping distance and limit the possibility of the dropped object causing damage. Tools or
materials should not be suspended by an attached lanyard. Figure D-8 illustrates the proper use
of a lanyard.

Figure D-8
Example of Lanyard Use

D-37
Lanyards should not be secured to small-diameter tubing or other equipment that could easily be
damaged if the attached item is dropped.
D.6.9.5 Control of Activities Producing Particulate Matter
If practical, the component should be removed from the system to minimize particulate
contamination. Components that cannot be removed should be drained, wiped clean, and allowed
to dry to the maximum extent practical. When grinding or sawing to sever a system component
boundary, the actual penetration should be made by means that would introduce the least
possible debris or foreign material into the system. If possible, tubing cutters, clamshell cutting
machines, and portable lathes should be used to cut until the metal is thin; the actual breach
should minimize particle loss into the system.
Ventilation systems may introduce dirt and debris into the system or component and spread dirt
and debris to other areas. The following control measures should be considered, as needed:
Install temporary filters.
Redirect ducts or air flow.
Install enclosures such as glove bags or tents at the work site.
Install debris dams, plugs, or similar devices to prevent debris from entering the system
during activities that could generate particulate matter.
Install a removable film or adhesive cloth to line a component cavity to aid in later cleanup.
Stellite debris generated from activities such as valve grinding or lapping are of particular
concern because those particles can become highly radioactive after passing through the reactor.
Good work practices and thorough close-out inspections are necessary to ensure that Stellite
debris is not allowed to enter or remain inside primary plant systems.
D.7 Recovery of Loss of FMEA Control
D.7.1 Initiation of a Condition Report
A condition report should be generated to document conditions constituting a loss of FME
control, as defined in plant or site procedures; however, efforts to resolve the issue can proceed
prior to initiating the condition report, if appropriate for the situation. If the loss of FME control
involves unresolved log-keeping discrepancies (for example, unlogged items in an FMEA or
logged items unaccounted for), the job supervisor should determine the likelihood of foreign
material intrusion having occurred. If intrusion is possible, efforts to locate and recover the
material should be implemented. The job supervisor may temporarily defer efforts to recover
foreign material until a more appropriate point in the activityif the material poses no imminent
threat to personnel or equipment and a record of the material and its location is recorded in a
condition report.

D-38
If foreign material intrusion has occurred and the material involved poses a threat to primary
plant systems or fuel assemblies, plant operations should be immediately notified.
D.7.2 FME Recovery Plan
Plant personnel should not attempt recovery of foreign material that is not immediately
retrievable until a written recovery plan has been formulated and approved by key stakeholders.
Recovery plans should specify, as appropriate for the situation:
Information currently known regarding the foreign material (for example, its location,
identity, amount)
Why the foreign material is not considered immediately retrievable (for example, ALARA
concerns, inaccessible location, potential to migrate further within the system)
The impact the material may have already had on the plant
Any measures that will be implemented to prevent the material from spreading or migrating
to other areas (for example, installation of FME devices)
Measures to address any ALARA and/or industrial safety concerns associated with recovery
efforts
How the material will be located (that is, use of borescopes, radiography, remotely operated
video cameras, fiber optics, infrared thermography, etc.)
How the material will be recovered (that is, use of grappling devices, reach rods with
attached adhesives or magnets, vacuuming, system flushes, radiography, robots, etc.).
Whether further inspection or disassembly of equipment is required to facilitate recovery
efforts, and how this will be accomplished
A monitoring plan for ensuring that potentially impacted equipment is functioning normally
following its return to service
Supervisors should initiate activities to recover foreign material that is not immediately
retrievable in accordance with the recovery plan. The concurrence of the responsible department
manager should typically be obtained prior to terminating unsuccessful efforts to retrieve foreign
material.
D.7.3 Foreign Material Retrieval
Maintenance personnel should return the work package to the planner or supervisor for scope
changes or additional requirements for post-recovery inspection and acceptance criteria, if
appropriate. Foreign material may become highly contaminated after contact with certain
systems or components. Retrieval should not be attempted on contaminated systems or
components without specific approval by Health Physics.

D-39
Retrieval actions should not introduce more foreign material into the opening or cause the
foreign material to penetrate even further into the system or component. Engineering may be
consulted to assist in the retrieval method. Foreign material location may be determined by
visual inspection, fiber-optic techniques, mirrors, or remotely operated TV cameras.
If retrieval is not immediate, an action plan should be in place and scheduled to prevent retrieval
activities from causing unnecessary outages or delays. The following methods for retrieving
foreign material should be considered:
Using special snakes with grapples
Using adhesives or magnets
Disassembling the component
Vacuuming
Flushing
Installing temporary screens or strainers to catch items if flushing is required
Important decisions the supervisor should weigh before any additional actions are initiated that
could make the situation worse are:
Can the foreign material be easily and reliably retrieved?
Could the foreign material reposition during recovery, and create a more difficult recovery?
Should a multi-discipline team be formed to direct the recovery?
Could the foreign material break apart during retrieval?
For foreign material that cannot be readily retrieved, the following actions should be considered:
Observe the final location of the material dropped.
Record any appropriate remarks on the control log.
Report any loss or suspected loss of material within systems or components to supervision
and operations as appropriate. This is a management expectation and an essential element of
a quality FME program.
Return the work order to the planner or first line supervisor for a scope change to add
additional requirements for post-recovery inspection and acceptance criteria.
Initiate a condition report according to the corrective action program for any loss or
suspected loss of material in an FMEA. The condition report should document the condition,
the foreign material quantity (2 bolts, 1 tie cable, etc.) to the extent practical, and any
immediate corrective actions. If there is uncertainty, the supervisor or FME coordinator
should be contacted for assistance.

D-40
D.7.4 Recovering Foreign Material After Returning the System to Service
If foreign material will not be recovered from a system prior to its being returned to service, then
the supervisor should open an action within the existing condition report for appropriate
engineering personnel to perform an evaluation. Engineering should evaluate the potential
impact of nonrecoverable foreign material in regard to personnel safety, nuclear safety,
radiological safety, and plant reliability. The evaluation should include justification for returning
systems or components to service despite the presence of the foreign material.
As appropriate, the chemistry department may be consulted to determine the chemical effects of
the material on system materials, equipment, or water chemistry.
If foreign material has entered or could migrate into a primary plant system, the nuclear fuel and
analysis organization should assess the potential impact to nuclear fuel.
D.8 Close Out of a Foreign Material Exclusion Area
If direct access to a system or component is not required, in most cases the FMEA may be
temporarily closed. Maintenance personnel should review the FME control log, if applicable to
ensure tool and material accountability, and return the log to the appropriate supervisor. Systems
or components should be restored to their normal operational condition after work completion. If
normal system configuration cannot be re-established, a temporary closure device should be
installed over any opening not being actively used for work.
If breached areas were not sealed with temporary covers while unattended, an independent
inspection to verify that foreign material is not present should be performed. To the extent
possible, maintenance personnel should ensure that unneeded tools, equipment, material, and
debris are removed and good housekeeping requirements are met. Maintenance personnel should
inspect the cleanliness of each item being closed as follows:
Verify the absence of foreign material. If required, use a camera, fiber optics, mirrors, or
other tools in areas where material could have fallen out of the direct line of sight (for
example, transition areas from vertical to horizontal).
Verify that the cleanliness of the existing systems and components has not degraded beyond
the as-found cleanliness.
If the cleanliness is unacceptable, submit the unacceptable results to the responsible
supervisor for an engineering evaluation; or clean the unacceptable area, and verify that the
cleanliness of the cleaned area is acceptable.
Document the cleanliness just prior to closing the system or component.
Work inside the drywell and torus should include good housekeeping practices on a task-by-task
basis to support FME. Final close-out inspections provide an additional barrier to support FME.

D-41
Maintenance on building spray or systems that interface with the borated water storage tank
could result in blockage of the reactor building spray header or associated nozzles. A loss of
FME control in these areas requires a documented visual inspection or surveillance testing to
validate operability.
Tools should not be stored in control, instrument, buss, or breaker cabinets because tools can
become missiles during a seismic event.
The space above the FME areas should be inspected as appropriate for uncontrolled or loose
material. Operational experience (OE) has shown that items have been dropped from cranes,
scaffolding, and platforms into the FMEA. Systems or components with hidden areas are of a
particular concern during final inspection because any item dropped or left behind may not be
seen during a close-out inspection without further disassembly. Examples include any of the
following:
Valves or other components in vertical piping runs or above closed vessels
Primary side of a steam generator with nozzle dams removed
Electrical enclosures, for example, switchgears, motor control centers, or control cabinets
Open electrical conduits and buss ducts
Breakers, transformers, and motors
OE has shown that condensers are common places to find foreign material. If a turbine
component or piping is opened above, allowing access to the condenser, a foreign material
inspection should be performed.
Maintenance personnel should remove any FMEA identification signs. The supervisor or
designee should perform a final foreign material inspection and review the FME control log to
ensure tool and material accountability; document these inspection results on the work package
instructions, cleanliness data sheet, or the plant/site FME control plan.
D.9 References
1. FME Guidelines: Revision 1 of TR-106756. EPRI, Palo Alto, CA: 2005. 1009707.
2. Steam Generator Foreign Object Task Force Review Material. EPRI, Palo Alto, CA: 2006.
1012921.
3. Foreign Material Exclusion Program, Procedure MA-AA-716-008. Revision 2, Exelon
Nuclear, Warrenville, IL.
4. Foreign Materials Exclusion Program, Procedures OPGP03-ZA-0014, Revision 7. STP
Nuclear Operating Co., South Texas Project, Palacios, TX: 2005.

D-42
5. Turbine-Generator Foreign Materials Exclusion Zone Performance Guide, 8
th
Edition. STP
Nuclear Operating Co., South Texas Project, Palacios, TX: 2005.
6. Foreign Material Exclusion Requirements for Outside Contract Construction Personnel.
AmerenUE, St. Louis, MO: 2004.
7. Foreign Material Exclusion Program, Procedure MNT-NGGC-0007, Revision 6. Progress
Energy, Nuclear Generation Group, Raleigh, NC.
8. FGD Foreign Material Exclusion, Procedure MNT-FGDX-00020, Revision 0. Progress
Energy, Fossil Generation Department, Raleigh, NC: 2003.
9. Turbine Foreign Material Exclusion (FME), Procedure SA1-7 FME 0001 PS, Revision 0.
FirstEnergy, Akron, OH: 2004.
10. Foreign Material Exclusion, Nuclear Procedure N-PROC-MA-0018, Revision 7. Ontario
Power Generation, Pickering Nuclear Plant, Pickering, ONT: 2006.

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Over Haul of Steamturbine

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Electric Power Research Institute

C) temperature mismatch is considered H

C) (Off wobbulator at 3000 rpm)

C) [inlet to drain delta T]

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