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Abstract
This section discusses the purpose of and general principles for shop inspection and
testing of drivers (and electric generators). It covers several quality-control tests,
giving general guidance on when the respective tests may be cost-effective and
appropriate.
Contents Page
In most cases, the rated-temperature vibration test is done at the same time as the
heat run for the “Complete Electrical Tests. ” Large 3600-RPM induction motors,
commonly applied for high-speed centrifugal pumps and compressors, should be
subjected to this test sequence to avoid problems after installation. They are much
more susceptible to mechanical problems than lower-speed motors.
fuel supply or a large enough load device in their test facilities. As a result, many
engine tests are either performed in the field or waived by the user.
A. Factory Test
Due to limited facilities, factory tests are usually standardized, and few if any
customer special tests are performed. The standard factory tests may be witnessed
at the purchaser’s option. Tests are performed on the bare engine using test cell lube
system, cooling system, controls, etc. The engine load is usually a water brake.
Factory test procedures include a run-in after the initial start, variable load testing
(within shop capabilities), overspeed trip setting, and limited post-test dissembly
for inspection. A typical load test might be performed as follows:
• Full rated load—1 hour
• 110% rated load—30 minutes
• 75% rated load—30 minutes
• 50% rated load—30 minutes
The main objective of the load test is to determine brake-specific fuel consumption.
Other operating conditions such as firing pressures and temperatures, as well as
temperatures throughout the engine are recorded.
A posttest disassembly for inspection is only warranted for the most critical
machines. It should include the following:
• Record bearing clearances and web deflections
• Boroscopic inspection of cylinder liners
• Visual inspection of one or two piston/connecting rod assemblies (requires
removal from engine)
• Record valve lash
• Visual inspection of valves in one head
• Remove and inspect one main bearing
• Retorque all main bearing caps
• Inspect crankcase and filter for metals or babbit
• Pressure test water jacket for 30 minutes
Witness of specific inspection points may be negotiated with the engine manufac-
turer. Depending on amount of disassembly, it is sometimes appropriate to run the
engine at full-rated load for 1 hour after reassembly.
B. Packager’s Shop Test
On generator sets it is sometimes possible to shop test the entire machinery train on
its skid complete with job auxiliary systems and controls. The benefit of
performing a packager’s shop test is that all of the auxiliaries and controls can be
tested (and debugged if needed) in the shop. Problems are discovered and solved
prior to acceptance in the packager’s shop where all the resources for correction are
available. Such problems tend to be time consuming and costly if left for discovery
in the field.
The primary factors that limit packager’s shop tests are:
• Fuel availability
• Lack of heat exchange equipment
• Load bank and electrical system limitations
A typical packager’s shop test will include the same load test durations as the
factory test. In addition the test might include a heat-run at full load for 4 hours to
allow for thermal stabilization. A comprehensive record of temperatures and pres-
sures is logged during the heat-run, recordings taken every 10 to 15 minutes.
C. Field Tests
Field performance tests on engines are cumbersome and of limited value. It is often
difficult to measure and control the engine load and difficult to accurately measure
the fuel flow rate and its heating value. When a field performance test is done to
demonstrate guaranteed performance, the manufacturer should have a representa-
tive present, and the test procedures and conditions should be agreed upon prior to
commencing.
It is usually necessary to perform third-party emission tests on all internal combus-
tion engines to obtain operating permits from the local air pollution control authori-
ties. More information on these tests can be found in Section 300 of the General
Machinery Manual.
verify no yielding or distortion has occurred. Record the serial number of each part
or identify in some manner to verify parts are not switched with other jobs during
assembly. Witness NDE of any other parts for which witness is specified.
C. Balance of Rotors
Witness final dynamic balance of assembled rotor or rotors. Visually inspect all
blades, and verify blade fit is correct and blade retaining means is properly
installed. At this time (or during the prior visit) visually inspect all other major
engine components for casting quality, weld quality, obvious machining errors, and
damage; record serial numbers on parts or otherwise identify them.
D. During Engine Assembly
Visit during engine assembly to ensure that previously inspected parts are in fact
being used (manufacturer’s frequently switch parts.) Verify to the extent possible
that assembly procedure is in compliance with the manufacturer’s standards. Verify
that running clearances are measured and checked against the manufacturer’s toler-
ances. Two separate visits may be necessary (one for the compressor section and
one for the power turbine) but the inspector does not normally witness the entire
CGT assembly process.
E. CGT Performance
Witness performance test of the CGT, following approved test procedure.
F. CGT Final Inspection
Final inspect the CGT to verify that all components and appurtenances that belong
to the engine are installed (most CGT’s are tested using test cell equipment
including fuel control valves, gages, and filters.) This inspection can be accom-
plished during final inspection of the equipment package if the CGT is part of a
package that includes the driven equipment.
G. String Test
Witness “string test” of the completely assembled equipment package if a string
test is specified.
H. Shipping and Packing
Inspection for proper shipping preparation and packing may be warranted.
Numerous standards have been prepared over the past 25 years in an effort to guide
the turbine manufacturing industry and its users toward common goals for safety
and environmental compliance. An industry committee was formed to consolidate
and recognize the necessary technical disciplines while providing a comprehensive
gas turbine procurement standard under the auspices of the American National Stan-
dards Institute (ANSI).
In 1982 the American National Standards Committee B133 reorganized itself as the
“ASME Standards Committee B133 on Procurement Standards for Gas Turbines.”
Standard B133.6-1978 relates to gas turbine ratings and performance under speci-
fied site conditions under which the turbine is intended to run. This standard forms
the basis by which a purchaser can specify and understand test results as they relate
to the turbine’s specific site conditions.
Recognizing the specialized nature of petrochemical installations, the American
Petroleum Institute (API) published its own standard in 1982, Type H Industrial
Combustion Gas Turbines For Refinery Services, API Standard 616. As the title
suggests, this standard addresses petroleum industry needs; therefore, many differ-
ences will be found between it and ASME B133. However, 133 and 616 compli-
ment each other—616 simply addresses API needs more fully.
The rating conditions in this case take into account the site conditions as an
average, rather than stating International Organization for Standardization (ISO)
standard conditions. Conversion curves are used by the manufacturer to convert and
compare empirical data to ISO conditions.
Emissions
Emissions or compliance testing is one of the most difficult and exacting proce-
dures that can be carried out. Depending on the local regulatory laws and the
operating conditions under which the turbine will operate, emissions levels may be
mandated at such a low level that detection instrumentation and analyzers are inca-
pable of carrying out the specified tasks at the specified levels of accuracy. It is
highly recommended that an outside consultant or Company specialist be
contracted early in the project planning stage to assist with the emissions compli-
ance planning. Section 300 contains references on where to get additional guidance
on emissions. Section 400 contains information on CGT emissions.
Typical controlled emissions are:
1. Oxides of nitrogen
2. Carbon monoxide
3. Particulates
4. Ammonia (If a selective catalytic unit is used)
5. Noise
6. Reactive organic compounds
7. Sulfur dioxide
Sulfur dioxide emissions are usually at a minimum due to the controlling laws for
sulfur content in combustion fuels.
An example of a highly regulated area, such as Southern California, will exhibit
stack emissions limits in the range of:
Oxides of nitrogen 24-Hr. limit —300 lb
15-Min. Ave. limit—9 PPM
Carbon monoxide 24-Hr. limit—49 lb
15-Min. Ave. 10 PPM
Particulate matter 175 lb per day
Noise 85 dB—3 ft from the
enclosure
Reactive Organic 75 lb per day
Compounds
Vibration Testing
Vibration testing is primarily performed in the factory at the time of rotor construc-
tion. However, for large industrial turbines, this is usually done on each component
rather than on an assembled turbine generator train. The completed installation will
be observed for proper vibration levels during the initial startup if that has not
already been done in the factory.
installation. Package testing also provides the opportunity to debug and repair the
entire system before it leaves the factory.
Typical tests and requirements that would be required at the factory are:
1. Acceleration rate
2. Speed range control
3. Demonstrated stable operation for at least 4 hours
4. Contract seals and bearings are used during tests
5. Lubrication system operates within design spec during testing sessions
6. Operation free of all leaks and safety hazards
7. Protective and control devices checked
8. Auxiliary gear units included in tests
9. Vibration amplitudes and frequencies recorded
10. Control system functions verified
Depending on the scope of the turbine purchase, several supplemental tests are
available to check load gears, noise, starting means, etc. The preceding list is an
abbreviated description of tests that require clarification of specifics for the turbine
package being purchased and tested.
Standards that would be appropriate to apply to these tests are listed in API,
NEMA, IEEE and ASME guidelines. An example of this application would be API
670, to govern the vibration probe installation specifications or API 614 utilized as
the governing tool for the lubrication system. Company DRI-MS-3547 and IEEE
115 Standards are appropriate for many of the generator tests that are required. The
purchaser must become familiar with these standards to formulate a purchase speci-
fication that protects the client’s interests and minimizes costly downtime.
Chevron has considerable experience in this field, and it is highly recommended
that a Company specialist be consulted for preparing a test plan/specification.
Load tests
Functional testing consists of testing of the turbine generator or mechanical drive
package under various operating conditions, for example, underexcited, overex-
cited, base load, peak load, power factor control, and VAR control.
The preceding field tests are time consuming and require precise coordination
with the operating personnel, interfacing utilities, and regulatory agencies.
Many of the tests are performed at load levels that create operating conditions
which produce emissions in excess of the plant operating permit conditions. An
example of this would be the period of time taken to boil out a heat recovery steam
generator. This procedure, depending on the size of the turbine, requires the turbine
to be operated at very low exhaust temperature levels for several hours. A plant
operation that requires catalytic devices to reduce emissions for compliance will not
be able to achieve sufficient temperature to activate the catalysts during the boilout
period. Care must be taken to ensure that the negotiated operating permit allows for
transient operating conditions, startups, shutdowns, and low load.
Generators that are paralleled with the local utility grid can be disruptive should a
mishap occur. Representatives of the local utility will require close communication
during initial synchronization and the load tests that follow.
Field performance testing is the final step toward verifying that the purchaser has
received what was contracted for. The performance tests, governed by ASME B-
133 guidelines, are usually conducted with a minimum amount of running time on
the turbine or following a turbine wash to ensure optimum performance. It should
be noted that this test may not be necessary if the manufacturer and purchaser have
agreed upon the results of a series of factory tests. However, factory tests do not
have the site conditions, the fuel and supply system, nor the steam or water injec-
tion system that the final installation does. Therefore, it is highly recommended that
these tests be carried out to verify that the installation satisfies all contract obliga-
tions.
The field performance tests, as described in Sub-section 881, are performed by a
team of Company and turbine manufacturer personnel. The tests are conducted
Recommended Use
The checklist is presented in sequential order. Each step is intended to be self-
explanatory. As each step is completed, a notation can be made on the line at the
right. All blanks should be filled in.
Fig. 800-2 Checklist for Conducting an API Special-Purpose Steam Turbine No-Load Run Test (1 of 4)
1. Documents to have on hand
API 612 (Edition in effect at time of purchase) _______
API 670 (Edition in effect at time of purchase) _______
DRI-EG-3664 (Edition in effect at time of purchase) _______
Final purchase order _______
Contractor’s purchase specification _______
As-built design data sheet _______
Coordination meeting notes _______
Critical speed map and response analysis (See Section 800 for recommendations.); must include _______
effects of coupling used for test (if not the contract coupling)
John Sohre’s paper on testing of steam turbines _______
2. Before Test
Review API 612 (Purchase edition) _______
Review DRI-EG-3664 (Purchase edition) _______
Review manufacturer’s Operating Manual, if available _______
Discuss manufacturer’s prerun test experience with Chevron inspector, if any, Contractor’s
inspector and manufacturer’s engineering, quality assurance, and test floor personnel (Manu-
facturer should already have run subject turbine to anticipate outcome of witnessed test. A full
or partial load test may have also been run.) _______
Develop list of last-minute “problems” discovered by the manufacturer _______
Each problem has been satisfactorily rectified (Use purchase specification, manufacturer’s
specification, and own best judgment as guides. Put yourself in the place of the plant operator.) _______
Using a copy of the critical speed map, plot the manufacturer’s calculated 1st and 2nd criticals
[The critical(s) found during testing is within ± 5% of critical speed(s) predicted by the manufac-
turer.] _______
Have design data sheet available _______
The Contractor’s inspector is normally the official Company spokesman. Work with and through
him. _______
3. Pretest Inspection
Check with test foreman to make sure job bearings are installed. _______
Check to be sure that contract proximity probes, including axial probe(s), are installed, gapped,
and calibrated _______
Check to see that contract coupling half and idling adaptor are in place. Adaptor must weigh
about 1/2 of contract spacer spool. If contract coupling is not available, shop coupling of same
weight and center gravity can be substituted. Critical speed map and response analyses must
be rerun to include effects of substitute coupling _______
Fig. 800-2 Checklist for Conducting an API Special-Purpose Steam Turbine No-Load Run Test (2 of 4)
If substitute coupling is of different size, record weight and center of gravity of substitute
coupling and adaptor combined
weight_______________lb
c.g._________________in. from_____________________end
Steam supply temperature does not exceed design condition. Ratio of inlet to discharge pres-
sures approaches design value as closely as possible. Inlet steam pressure may be lowered to
avoid overheating casing exhaust end. (See API 612 Paragraph on Standard No-Load Running
Test.) _______
All vibration readouts are hooked up to an oscilloscope and are calibrated. Readout voltage
should be about mid-range, 7 to 8 V, D.C. (Scale-and-pointer type readouts may have suppres-
sion and could read differently from scope especially if nonsynchrous vibrations are present.) _______
Test stand oil is:
150 ssu @ 100°F. The brand name is _______________________________,
type_______________, vis.______________________________________.
Clean 10-micron nominally rated lube-oil filter is in place. _______
4. Test Run (without Vibration Analysis Travel Kit)
Maximum allowable runout (mechanical and electrical combined) determined at slow roll does
not exceed 0.25 (12,000/nmc)0.5 mils _______
Bearing and lube-oil temperatures have reached equilibrium; this normally takes an hour at
maximum continuous speed _______
Oil inlet temperature and pressure are as specified by the manufacturer on data sheet (Should
also be within allowable range in Operating Manual. _______
Machine has no steam leaks at labyrinth seals or flanges _______
Gland condenser (if any) cooling water temperature is as specified _______
Gland condenser (if any) cooling water pressure drip is less than 5 psig _______
There are no oil leaks at fittings, along the shaft, at the hydraulic servo (if fitted), or at the
governor _______
Temperature rise across any bearing is about 40°F maximum during this no-load test. (An oil
temperature rise of 50°F, with 110°F ambient—"under worst conditions"—will be the maximum
allowable in the field.) _______
(If bearing oil temperature is too high, check for overly restrictive orifice or passage in oil supply
line and bearing clearances which are too tight.) _______
Vibration level as measured at any probe position does not exceed (12,000/nmc )0.5 mils, peak-to-
peak (This allowable incudes all runout.) _______
Vibration amplitude at any bearing is not affected adversely as oil supply temperature is varied
within operating manual limits (If amplitude increases, use tunable filter or real time analyzer to
look for fractional-frequency whirl.) _______
Fig. 800-2 Checklist for Conducting an API Special-Purpose Steam Turbine No-Load Run Test (3 of 4)
If maximum operating speed is above the first critical speed, find the first critical by vibration
amplitude peaking or by a clear-cut phase shift; unbalance the rotor if necessary—mid-span
unbalance is best, but coupling unbalance is okay if mid-span is inaccessible (Try to get Vendor
to use an unbalance weight equivalent to one gravity (maximum) at maximum continuous speed.
Use the formula below.) _______
Wu × ru = 35,200 × Wr/n2 mc
Wu = Unbalanced weight, lb
ru = Radius of unbalance weight, in.
Wr = Rotor weight, lb
nmc = Maximum continuous speed, RPM
(Document unbalance weight location, amount of weight, radius from shaft center line.)
There is no rapidly increasing vibration amplitude as the machine reaches trip speed (If there is,
this may be an indication that machine is running too close to its 2nd critical.) _______
Governor is properly set to provide smooth (no hunting) control from minimum to maximum
continuous rated speed as control air signal is varied from 3 to 15psig and is repeatable _______
All control linkages are free to move without binding, but not too sloppy _______
Overspeed trip functions between -1% and +2% of manufacturer’s trip set point (RPM) on each _______
of three successive tries (No trends up or down in successive trips.)
1.____________ RPM 2.____________ RPM 3.____________ RPM
All safety trips function at specified points (A reasonable allowance for adjustment above and
below this point should be provided.) _______
All required (if any) noise data has been taken and recorded _______
All test results have been properly recorded and certified on manufacturer’s SHOP TEST REPORT _______
5. Posttest Run Inspection
All journal bearing and thrust pad surfaces are in like-new condition or satisfactorily restored
with minimal efforts (The use of abrasive coated cloth (such as emery or crocus cloth) is
strongly discouraged for this task) _______
a. Light scratches acceptable
b. Shiny areas indicate uneven bearing surface preparation; this is normally the result of hand
scraping (If found, the bearing should be further scraped and blue-dye checked until most of
the bearing surface shows contact with the journal.)
c. If bearing is wiped, check clearances and adequacy of oil supply passages (Normally, the
bearing should be honed and retested.)
d. If bearing is scored or cracked, lubrication system has failed or allowable bearing loading
has been exceeded and the test must be rerun
If turbine has to be disassembled to make a correction, the entire test must be rerun. (See API 612
Paragraph on Standard No-Load Running Test.) _______
Fig. 800-2 Checklist for Conducting an API Special-Purpose Steam Turbine No-Load Run Test (4 of 4)
6. Electronic Analysis
If the Vibration Analysis Travel Kit (or manufacturer’s equivalent) is available, the following addi-
tional tests should be performed before and during the mechanical running test:
Get slow roll data at less than 500 RPM (Confirm that run-out (mechanical and electrical
combined) is no more than 0.25 (12,000/nmc)0.5 mils) _______
Simultaneously record vibration amplitude and phase versus RPM on an X-Y-Y' plotter (Do this
on run up to trip and coast down from trip.) _______
Repeat above step as bearing oil temperature is varied _______
If temperature sensors are available, record oil and other temperatures on a multipoint recorder _______
Use Real Time Analyzer and X-Y-Y' plotter at 250 to 500 RPM intervals from slow roll to trip speed
to look for the frequency of vibration peaks (Watch carefully for frequency of 40 to 50% RPM ×
RPM, first critical speed and multiples of RPM up to blade or vane passing frequency.) _______
Try to determine mode shape of shaft at critical(s) using phase information from both ends of
shaft (Use shaker on spare rotor (if available) to find natural frequencies and mode shapes.) _______
Plot D.C. voltages (X and Y) versus RPM for each journal to determine no-load running position
of journals within bearings (This can be compared later to fully loaded operation in the field to
monitor bearing deterioration.) _______