Chapter 6

MAINTENANCE AND
TROUBLESHOOTING

6.1 Lubrication Oil

In order that the oil rings may carry the oil to the top of the journals and
distribute it freely over the bearing surfaces, the oil itself must have the
proper properties under the existing operating temperatures. It must not
be so heavy (high viscosity) as to retard the action of the rings. An oil that
is too light (low viscosity), on the other hand, will not be able to maintain
the necessary film between the surfaces. As temperature has a positive
influence on the properties of an oil, it is necessary that an oil be selected
which will attain the proper properties at the operating temperatures to
which it will be subjected in actual service.

The time that an oil will last in a turbine varies according to operating
conditions. The continuous circulation of oil in a bearing results in a
gradual deterioration of the oil itself, due to the action of heat, moisture,
and air. Evidences of this deterioration are development of acidity,
increase in viscosity and the deposit of sludge or sediment.

The length of service that may be expected from the oil is dependent upon
many variables, such as stability, operating temperature, and rate of
circulation. Consequently, it is impossible to make any definite statement
in regard to the frequency of oil changes. Since the quantity of oil required
for ring-oiled bearings is small, good advice is to change the oil frequently.

6.2 Oil Cooling

Oil is usually cooled by cartridge-type, water-cooling coils.

6.3 Turbine Casing

The two halves of the casing are sealed with Permatex or other liquid
gasket such as oil and graphite. Top half casing is provided with tapped
holes for jack screws which are used to break the joint. There are no high
pressure joints inside this casing.

6.1
6.4 Steam Chest Assembly

The steam chest assembly can be removed as a unit simply by loosening

the nuts which hold it to the casing. On two nozzle turbines, the auxiliary
valve stand and hand valve are part of, and removed with, this assembly.

6.5 Blades

The rotor assembly, balance, and inspection to be done by specialized

technicians. A complete new wheel is rarely changed before the life time
which is in the order of 25 years.

6.6 Nozzles

To remove the nozzle, unbolt the steam chest assembly. The nozzle-
stand flange is then exposed, and this assembly slides out of the casing.
A dowel pin permanently fixes the position of both nozzle and stand with
respect to blades. When replacing the stand, make sure that the nozzle
outlet lines up with the blades and then redowel.

6.7 Carbon Rings

Leakage of steam along the shaft is prevented by carbon-ring packing. In

those so equipped, each packing box consists of a bronze split housing,
three carbon rings, bronze diaphragm, and cover. Garter springs which
hold rings together are stainless steel.

To renew the carbon rings, remove the top half of the turbine casing and
loosen the cover. Slide it back along the shaft; then, lift off the top half of
the packing box. This exposes the rings, which can easily be removed.
Make certain that the shaft and packing housings are free from rust or
scale.

To insert new rings, line them up so that the slots for the retaining pins are
at the top and on exact center with the shaft. Replace the top half
housing, using oil and graphite at the split. Next, replace the top half
casing and then pull up the cover. When the packing box is properly
assembled with rings seating and pins in slots, very little pressure is
required to pull up the cover. When in proper position, there is 1/16 inch
(1.58 mm) clearance between cover and housing. If clearance is greater,
the pins are riding on the carbon rings and it will be necessary to
dismantle and reassemble. The joint of the housing with casing is made
with Permatex or oil and graphite. Carbon-ring clearance on shaft is 0.002
inch (0.005 cm).

6.2
6.8 Bearings

In turbines, bearings are babbitt-lined, sleeve-type, ring-oiled, and

horizontally split, mounted in cast-iron, split brackets. They may be rocked
out of position and replaced after removing the bearing caps.

Governor end bearing is babbitt-faced at both ends and serves as a thrust

bearing as well as radial bearing. This bearing has radial oil grooves in
both ends for lubricating the thrust faces. Running clearance between
each thrust face is 0.004 inch (0.010 cm), or 0.008 inch (0.020 cm) total
for both faces.

Coupling end bearing has oil collector grooves in both ends with drain
holes in lower half.

Replacement of bearings require scraping and fitting to the shaft, so that

the running clearance will be 0.003-0.004 inch (0.007-0.010 cm). Also the
governor end bearings should be scraped on both ends to fit into the
space occupied by the old bearing. If necessary, the locating collar, which
is set-screwed to the shaft, can be shifted either way to match the new
bearing.

While fitting the bearings, make certain that the rotor is equidistant
between the nozzle and the reversing nozzle. Clearance at the nozzle and
also the reversing nozzle is 1/32 inch (0.794 mm).

Each bearing cap has a tapped opening at the top for filling the oil
reservoir. Through these openings, the operator can view the oil rings to
make certain that they are turning with the shaft.

6.9 Over speed Valve Assembly

To remove the over speed valve assembly, first disconnect the trip link
and then remove cap screws from the valve cage. The joint with the steam
chest is broken by two jack screws which are inserted into tapped
openings provided for this purpose. The basket type steam strainer is
removed with this assembly.
Remove the strainer by taking out two screws. Unscrew the trip steam
knob and nut, both right hand threads. Lift off the spring, loosen the
packing nut, and push the valve stem through the packing. Unscrew the
recessed pipe plug from the lower end of the trip valve and push out the
valve stem. Reverse this procedure when reassembling. Clearance
between trip lever and governor hub is 1/16 inch (1.58 mm). Adjust at the
trip link.

To renew the trip valve packing, unscrew the knob and nut (right-hand
threads), lift off the spring, unscrew the packing nut, and then pull old
packing. Replace with packing ordered from the factory. Work in by

6.3
pushing stem down by hand. Make certain that the stem works freely
before starting the turbine.

6.10 Over speed Governor

Trip plunger moves outward, striking a lever, which releases a latch and
permits spring to close trip valve. Do not attempt to reset the valve until
steam pressure has been relieved. To relieve pressure, close the throttle
valve in steam line and open the hand valve which was installed at turbine
inlet flange.

To raise the trip speed, remove the inspection cover, loosen alien head
screw, and then tighten adjusting nut. A slight turn of this nut will increase
speed considerably. Be sure to tighten the setscrew after any adjustment.

Check over speed valve at least once each week by hand tripping. Simply
disengage the trip latch, which allows the valve to close. Also check trip
plunger periodically to make certain that it is free to move outward. This is
done by inserting a blunt nosed rod through the hole in the adjusting nut
and pressing down against spring tension.

6.11 Governor Valve

Take off the governor lever bracket and loosen the cap screws in the
flange of the steam chest head. The steam chest head and governor valve
may then be pulled out. This exposes the valve cage, which may also be
pulled out. The pin is set for 1/64 inch (0.397 mm) clearance at steam
chest head.

6.12 Governor Valve Packing

Take off the bracket, unscrew the nut, unbolt the cradle, and then pull the
old packing. Replace the packing ordered from the factory. Never fill the
box completely full. After assembling, work the stem by hand to make
certain that it is free. Never use standard square packing. Use only conical
packing.

6.13 Speed Governor

Disconnect the bracket, withdraw the governor plunger, remove the top
half governor housing, and unscrew the governor nut (right hand thread).
Then the governor spring with spring seat, plunger seat, and fly balls can
be lifted out. Before unscrewing governor nut, be certain to note its exact
position on the shaft so that it can be replaced in the same location.

6.4
To inspect or renew the governor plunger or ball bearing, simply
disconnect bracket and draw out plunger assembly. No other parts need
be disturbed.

6.14 Speed Adjustments

Speed may be changed while turbine is in operation. Turning the

governor adjusting screw to the right reduces speed, while turning to left
increases speed. A total adjustment of about 20% or approximately 10%
above and 10% below normal, may be made in this manner. Additional
speed adjustment of about 5% may be made, after shutting down the
turbine, by tightening or loosening the governor nut on the end of the
shaft. Governor nut is accessible through inspection window after
removing the cover.
Adjustment for speeds to about 50% below normal can also be made,
while in operation, by further tightening the adjusting screw, but the
governor will be inoperative over this range. Operation of the turbine will
be satisfactory, provided the load of the driven machine is fairly constant
and the steam pressure does not fluctuate to any great extent.

6.15 TURBINE TROUBLESHOOTING

Here are a few troubles that may be encountered from time to time,
together with their probable causes.

A. Vibration

1. Bent shaft.

2. Worn bearings.

3. Coupling out of balance.

4. Driven machine out of balance.

5. Misalignment between turbine and driven machine. Check when

turbine case is hot.

B. Stuffing Boxes Leaking Steam Along Shaft

1. Clogged drain line.

2. Carbon rings improperly installed.

3. Worn carbon rings. Check and replace if necessary; clean and polish
shaft surface at the same time.

6.5
C. Governor Hunting

1. Worn or bent valve stem.

2. Worn or fouled governor plunger.

3. Lost motion in governor lever.

4. Governor valve sticking.

5. Governor valve or cage worn.

6. Worn governor ball-bearing.

D. Turbine Will Not Come Up to Speed

1. Speed governor out of adjustment.

2. Load of driven machine too great.

3. Nozzle-throat fouled by foreign matter.

4. Low steam-pressure at turbine inlet.

5. Low pressure at nozzle caused by partially closed valve in steam line,

clogged steam line, or clogged strainer. Check nozzle pressure at
tapped opening in top of steam chest, close to turbine case.

E. Turbine Speed Too High

1. Governor out of adjustment.

2. Worn governor valve or cage.

F. Bearing Failures

1. Misalignment.

2. Inferior or improper oil.

3. Improper fitting or oil grooving.

4. Thrust transmitted to turbine shaft from driven machine.

6.6
Bearing temperatures above 200° are not alarming on sleeve or ball
bearing machines. However, these higher temperatures require closer
attention to oil selection and more frequent oil changes.

6.7