蒸汽透平维修RLHA STEAM TURBINE MAINTENANCE.doc

BP Zhuhai Chemical Company Ltd.Revision: 1RHAL STEAM TURBINE MAINTENANCERLHA型蒸汽涡轮机维修MN-M-53Page 23 of 23Date: 2005/08/08BP Zhuhai Chemical Company Ltd.Zhuhai China MAINTENANCE WORK INSTRUCTION Work InstructionMN-M-53Zhuhai PlantRLHA Steam Turbine Maintenance Page 1 of 23Updated: 1RLHA型蒸汽涡轮机维修Date: Jul 21, 2005Prepared by: Cheng Quanming Approved by: Luysterborg BartRevised by: Approval Date: Aug 08, 2005WORK INSTRUCTIONIntroduction TimeInitial说明時間簽名This procedure is used for the maintenance of COOPUS Turbine RLHA19 & RLHA24 only. Two turbines speed are 2900rpm. Refer to drawing NO. 01H6251 08 (attached).本程序仅适用于COOPUS RLHA19及RLHA24蒸气透平。两蒸汽涡轮机的转速均为2900rpm。参考图号：01H6251 08 (附图).Warning: Most maintenance work have to do at field, high pressure and high temperature are two risks for this work, proper isolation and PPE are very important.警告: 大部分的维修工作必需在现场进行，主要风险来自高温高压，正确的隔离及PPE 是非常重要的。1Cover Removal and Replacement大盖的拆装1.1Remove the four bolts holding gland housing covers (211) to the cover (2), and four bolts from the horizontal flange of the gland housing.拆掉连接汽封盖（211）和大盖(2)的4颗螺栓，以及连接两汽封盖的4颗螺栓。1.2Remove gland housing covers (211) at vertical direction.垂直向上拆去汽封盖（211）。1.3Remove bolts from horizontal flange of the turbine.拆去大盖的紧固螺栓。1.4Break horizontal joint (cover/case mating surfaces) by inserting jacking bolts.用顶丝把大盖顶开。1.5Lift cover slowly and carefully so as to avoid damaging the rotor inside.小心拉起大盖，不要碰伤转子。1.6Rotate and remove the upper labyrinth seal from the cover, using care to prevent the loss of locating springs (700). Refer to Figure 1.将上部迷宫密封旋出，小心不要丢失了弹簧（700）。参考图1。 Figure 1: Labyrinth Seal Assembly1.7Remove all old sealant from surface of horizontal joint and others sealing surface把所有密封面的旧密封胶清理干净。Note: Dont file, gouge or scratch these surfaces.注意：不能锉、凿、刮这些密封面。1.8Check lower labyrinth seal and exhaust casing (1B), remove any foreign material检查迷宫密封的下半部分及排汽腔（1B），取出腔内所有异物。1.9Rotate and install the upper labyrinth seal to the cover, using care to prevent the loss of locating springs (700). Refer to Figure 1.将迷宫密封的上半部分旋进大盖，小心不要让弹簧（700）掉出来。参见图1。1.10Apply joint sealant as follow:按以下步骤涂密封胶：1.10.1Apply sealant (Turbo-R) to the horizontal joint of the lower half casing and gland housing, as shown in figure 2.按图2来给各密封面涂上密封胶（Turbo-R）。1.10.2Apply 1/8” (3mm) diameter Temp-Tite over the sealant, inside the bolt circle on the horizontal flange.将直径为1/8” (3mm) 的 Temp-Tite放在密封胶的上面，并置于水平法兰螺栓孔以内1.10.3Apply 1/8” (3mm) diameter Temp-Tite over the sealant, inside 3-way corner of casing, cover, and lower gland housing, approximately 1/8” (3mm) from the edge and extending outward.将直径为1/8” (3mm) 的 Temp-Tite放在密封胶的上面，并置于机座、大盖、及下部汽封盖这三机件的交汇处以内，离边缘大概1/8” (3mm)并向外延伸。Note: Turbo-R must heated to 38 in a metal container (dont exceed 49), and it must be thoroughly mixed with the correct proportion of X-1 catalyst (1 unit X-1 catalyst mix with 1 quart of Turbo-R).注意：Turbo-R 必须放于一金属罐内加热到38（不得超过49）,而且必须以正确的比例与X-1催化剂充分混合(一瓶X-1催化剂配一夸脱Turbo-R)。 Figure 2: Sealant Location Diagram1.11Apply high temperature anti-seize thread lubricant (Loctite C5-A) to the threads of all bolts.所有的螺栓涂上耐高温抗咬合剂(Loctite C5-A)。1.12Lower cover (2) onto lower half of casing, using care to avoid hitting the wheel.小心地把大盖盖上，别碰伤转子。1.13Align cover to lower half casing using the two dowel pins.用两销把大盖与腔体定位。1.14Install and tighten horizontal flange bolts in accordance with Figure 3 and Table 1. Tighten all bolts to level 1, then repeat the sequence at level 2, and if required, level 3.装上螺栓，按图3的顺序及表1的力矩值分三次上紧螺栓。 Figure 3: Horizontal flange bolt torque sequence Bolt size/PitchTorque LevelTorque (N-M)1 - 8 UNC123270346103488034Table 1: Applied bolt torque1.15Inspect interior of gland housing for foreign material and damaged or misaligned carbon rings (216).检查汽封腔内部看是否有异物，是否损坏，碳环（216）是否装好。1.16Apply sealant as follow:按以下步骤涂上密封胶：1.16.1Apply sealant to the cover and horizontal sealing surface of the lower gland housing, as show in Figure 4.按图4给汽封腔各密封面涂上密封胶。1.16.2Apply 1/16” (1.5mm) diameter Temp-Tite and flatten it, as show in Figure 4.按图4把直径为1/16” (1.5mm)的Temp-Tite放好并把它压平。 Figure 4: Sealant location on gland housing1.17Position upper gland housing (211) on turbine cover (2) and lower gland housing (211). Tighten bolts according to Figure 5 and Table 2.装上汽封盖上盖，按图5的顺序及表2的力矩值上紧螺栓。 Figure 5: Bolt torque pattern on upper gland housing Table 2: Applied bolt torque2Carbon ring removal and replacement汽封碳环的拆装Note: Carbon rings consist of 3 segments (215), when a carbon ring is replaced, all segments of this ring must be replaced at the same time. (Figure 6).注意：每个碳环由三块碳环段(215)组成，更换碳环时必须同时全部更换。（图6）2.1Carbon ring removal拆碳环2.1.1Disconnect leak-off piping system.拆掉泄漏排放管系统。 Figure 6: Grand Housing and Sealing Element2.1.2Remove the four bolts holding gland housing covers (211) to the cover (2) and four bolts from the horizontal flange of the gland housing.拆掉连接汽封盖（211）和大盖(2)的4颗螺栓，以及连接两汽封盖的4颗螺栓。2.1.3Remove gland housing covers (211).拆去汽封盖（211）。2.1.4Remove garter springs (216) and stop washers (214).拆去弹簧（216）及止动垫圈（214）。2.1.5Remove exposed carbon ring segments (215). Rotate remaining segments by rotating them around the turbine shaft (21).先拆掉上面的一块碳环段（215），再把其它的碳环旋出来。Note：Put 3 carbon ring segments together, dont confuse with others if we must use them again.注意：把每个碳环的三个碳环段放在一起，不要跟其它碳环段混淆。2.2Carbon ring install碳环的安装2.2.1Remove all old sealant from all casing/gland housing surfaces. 除掉大盖及汽封盖所有密封表面上的旧密封胶。Note: Dont file, gouge or scrape these surfaces, or damage the 90 degree corner where machined surfaces of the upper gland housing half meet. Such damage will prevent a leak-tight seal.注意:不能锉、凿、刮这些密封面,不能损坏上汽封盖机加工面相交处的90度的直角2.2.2Clean interiors of upper and lower gland housing halves (211). 把上下两汽封盖（211）清理干净。2.2.3Clean chrome plated surfaces of the shaft (21). Inspect chrome plating on the shaft. If plating is bubbled, split, or peeling, the shaft must be replaced.把轴（21）的镀铬处的表面清理干净。检查轴的镀铬层。如果镀铬层有起泡、裂开、剥落，必须更换轴。2.2.4Inspect the carbon ring diameter according to Table 3 item A, ensure the diameter is not exceed the Max. value, all carbon rings surface are clean and at good condition.根据表3的A项检查碳环的内径，确认它没有超出最大值，同时确认所有碳环的表面都清洁并处于良好的状态。2.2.5Replace carbon rings (215), garter springs (216) and stop washers (214).装上碳环（215），弹簧（216）及止动垫圈（214）。Note: Verify that stop washers (214) are in tab slots that locate at lower half gland housing and carbon rings. Be certain the correct relationship between carbon ring segments by matching dots stamped on each segment. Replace all segments. Figure 7注意：止动垫圈(214)必须放进下汽封盖及碳环的沟槽里。必须按每一碳环段上小圆点的标志来正确安装碳环（1点对1点，2点对2点，没有小圆点的一面向外）.同时更换所有碳环段。图7.slotDots Figure 7: Carbon ring segments installation2.2.6Install gland housing upper halves (211) according to the procedure specified in steps 1.15 through 1.17. Replace it if necessary.根据步骤1.15到1.17安装上部汽封盖。必要时更换汽封盖。3Casing labyrinth seal replacement更换迷宫密封3.1Remove the turbine cover according to the procedure specified in section 1.按第1部分的程序移开大盖。3.2Rotate labyrinth seal segments around the turbine shaft and out of the lower half casing. Using care to prevent loss of locating springs. Refer to Figure 1 for details.把下半部分的迷宫密封旋出。小心！定位弹簧容易丢失。参见图1。3.3Clean all components. Replace any part that is no longer serviceable.清理好所有的部件。更换所有不能再用的部件。Note: If the labyrinth seal inner was damaged, it must be replaced. Labyrinth seal segments must be replaced as a set.注意：如果迷宫密封的内齿被损坏，就必须更换。迷宫密封要整套更换。3.4Install labyrinth seal segments and springs into the lower half casing by rotating them between the shaft (21) and casing.把定位弹簧及迷宫密封的下半部分旋进机座。3.5Install labyrinth seal segments and springs into the upper cover. 把定位弹簧及迷宫密封的上半部分装好。3.6Install the turbine cover according to the procedure specified in section 1.按第1部分的程序装上大盖。4Bearing/Bearing housing replacement更换轴承/轴承箱4.1Sleeve-type journal bearing replacement更换轴套型的径向轴承 Figure 8: Bearing housing assemble, governor end . 4.1.1Remove the two bolts securing the governor mounting housing (315) to the governor end bearing cap (10).把调速器支撑架（315）与轴承座（10）连接的两螺栓拆掉。4.1.2Remove dowel pins and bolts in bearing housing (8, 10) horizontal joints.拆掉轴承座（8，10）上盖的定位销及螺栓4.1.3Remove the upper half bearing housing.移开轴承座上盖。4.1.4Slide oil rings (112) over to allow removal of upper bearing half.从上部轴承上移开甩油环（112）。4.1.5Raise the shaft (21) slightly (1mm) to expose the bearing split line and remove the upper bearing half (367).轻轻提起轴（1mm），使轴承从中分线处分开，取出轴承的上半部分（367）。4.1.6Rotate lower bearing half (367) out of the bearing housing (8, 10).把轴承的下半部分（367）旋出轴承箱(8, 10).4.1.7Inspected the bearing inner diameter and tolerance according to Table 3 item C and D, and ensure the bearing inner surface is at good condition.根据表3的C及D项检查轴承的内径尺寸，同时确认轴承内径表面状态良好Note: Correct mark and properly placed can avoid the mistaken and neglect when re-install.注意: 正确的记号及良好的摆放可以很好地避免重装时的错误和疏忽.4.1.8Inspect shaft journals according to Table 3 item C. Verify that the bearing journal is clean and undamaged.根据表3的C项检查轴颈。并确认轴颈是干净的，而且没有损坏。Note: If journals are worn or scored, the shaft must be replaced. Slight scratches or nicks can be removed by stoning or with crocus cloth.注意：如果轴颈有磨损或刮伤，必须更换轴。轻微的擦痕或刻痕可用油石或细砂布磨掉4.1.9Drain and clean bearing housing reservoirs.排掉轴承箱里的油并把轴承箱清干净.4.1.10Coat the journal and bearing inner surface with proper turbine oil.轴颈及轴承内表面涂上适当的润滑油.4.1.11Lift the shaft (21) slightly (1mm) to permit sufficient room to rotate the lower bearing half (367) into the housing.轻轻提起轴（1mm），以便有足够有空间把轴承的下半部分（367）旋进去。4.1.12Lower the shaft onto the lower bearing half (367).放下轴，让它落在轴承的下半部分（367）上4.1.13Snap the upper half of the bearing (367) into the lower bearing housing half (8,10), aligning the tab so that it fits into the milled slot.把轴承的上半部分（367）装上，轴承上的突出部分必须装进下轴承箱铣出的小槽里 Figure 9：The tap on the upper half bearing4.1.14Place the oil rings (112) into slots on the upper bearing half (367) and verify that they are free to turn.把甩油环（112）放进上部轴承的沟槽里，并确认其能自由旋转。4.1.15Refill to the proper level with clean oil.然后加进适量的干净的润滑油。4.1.16Apply a thin coating of oil resistant sealant (Loctite 510) to the horizontal joint of the bearing housing.在轴承箱的剖分面处涂上一薄层耐油的密封胶(Loctite 510)。4.1.17Position the bearing upper housing carefully, aligning the tab so that it fits into the milled slot, so as not to crush the sleeve bearing tabs.小心装上轴承箱的上半部分，轴承上的突出部分必须装进铣出的小槽里, 避免把轴承的突出部分压变形。4.1.18Insert and drive in the dowel/taper pins.装上定位销。4.1.19Install bolts and torque them to 75-88N-m.装上螺栓并用75-88N-m的力矩上紧。4.1.20Rotate shaft by hand and observe oil rings through inspection holes in the bearing upper housing to verify that rings rotate freely.用手转动轴，通过轴承箱上盖的观察孔确认甩油环能自由旋转。4.1.21Install bolt holding upper bearing housing half (10) to governor mounting housing (315).把调速器装上。4.2Thrust bearing replacement更换止推轴承4.2.1Remove the turbine rotor (21) according to Section 5.1.按第5.1部分的程序拆去转子（21）4.2.2Remove locknut (23) and lockwasher (113) from the turbine shaft (21).拆掉锁紧螺母（23）及锁紧垫圈（113）。4.2.3Using a suitable puller, remove the thrust bearing (33) from the shaft.用适当的拉拔器把轴承（33）拉出。Note: Before install the new bearing, check the inner and outside diameter clearance, ensure it is correct.注意: 装轴承之前，确认轴承的内径及外圈的配合尺寸都是正确的4.2.4Inspect the shaft, and verify the shaft is undamaged.检查轴，确认其没有损坏。4.2.5Heat bearing and install it on the shaft with the shield facing out.加热新轴承并把它装到轴上，注意：有防护盖的那一面向外。Note: The bearings temperature not exceeding 120.注意：轴承温度不能超过120。4.2.5Install locknut and lockwasher.装上锁紧螺母及锁紧垫圈。4.2.6Install the rotor into the turbine casing according to Section 5.2.按第5.2部分的程序装上转子及大盖。4.3Bearing housing seal replace更换轴承箱油封4.3.1Remove the turbine rotor (21) according to the procedure specified in Section 5.按第5部分的程序拆掉转子（21）。4.3.2Remove the coupling hub and key from the turbine shaft (21).从轴（21）上拆掉联轴器的轮毂及键。4.3.3Remove the thrust bearing (33) from the shaft according to Section 4.2按4.2的程序拆去止推轴承（33）。4.3.4Loose set screws, remove all labyrinth seals.松开所有的固定螺丝，取出所有的迷宫密封。4.3.5Place two new inboard labyrinth seals (387) on the turbine shaft (21), dont tighten the two set screws.先把两个靠里面的新迷宫密封（387）装到轴上（一边一个），不要上紧固定螺丝4.3.6Install the thrust bearing according to Section 4.2按4.2的程序装上止推轴承。4.3.7Install the out board labyrinth seal (387) on the drive end of the shaft (21), dont tighten the set screws.装上泵端轴上的外迷宫密封（387），不要上紧固定螺丝。4.3.8Install coupling hub and key on the shaft.装上联轴器的轮毂及键。4.3.9Replace turbine rotor (21) into the casing according to Section 5. Adjust labyrinth seal position as the rotor is lowered into the casing, ensuring that seals straddle bearing housing ends and are not damaged.按第5部分的程序装上转子。一边把转子慢慢降落，一边调整迷宫密封的位置，确保密封能正确就位而不被损坏。4.3.10Position labyrinth seals (387) so as to obtain the clearance shown in Table 3 item J.根据表3的J项所示的间隙定好迷宫密封（387）的位置。4.3.11Tighten set screws to lock labyrinth seals (387) into position on the shaft (21).上紧密封的固定螺丝以定好密封(387)的位置。4.3.12Lock set screws into place by staking the setscrew/labyrinth seal interface.通过打花固定螺丝/密封分界面等方法把螺丝锁死，以防松脱。4.3.13Apply a light but continuous fillet of sealant (Dow Corning 732) to seal faces at the shaft/labyrinth seal fit, on the external face of the seal.在密封的外表面、轴与密封的之间涂上一薄层连续的密封胶(Dow Corning 732)。4.3.14Install upper halves of bearing housings (8,10) according to the procedure specified in Section 4.2根据4.2的程序装上轴承箱（8,10）的上半部分。 Table 3: Major Fits and Tolerances, RLHA 19&245Rotor removal and replacement转子的拆装5.1Rotor removal拆转子5.1.1Remove the governor (313) and the pump coupling. 拆去调速器（313）及泵的联轴器. 5.1.2Disconnect the governor mounting housing (315)拆开调速器的支撑箱（315）。5.1.3Remove upper halves of bearing housings (8,10) according to Section 4.1.1 to 4.1.3按4.1.1到4.1.3程序拆去上部轴承箱（8，10）。5.1.4Remove turbine cover and gland housing covers (211) according to Section:1按1程序拆去大盖及汽封盖（211）。5.1.5Check and record the gap G and H according to Table 3. 根据表3检查并记录G及H的间隙.5.1.6Lift the rotor assembly from the casing. Use extreme care when lifting the assembly to avoid damaging the wheel, blades, shaft, sector (15), or oil ring(112).把整套的转子从机座上吊起来。小心操作，以免损坏叶轮、导流片、轴、中间扇形导流件（15）、甩油环(112)。5.1.7Place rotor assembly on the support.把转子放到稳固的支撑架上。5.1.8Remove the carbon rings according to Section 2.1按2.1程序拆去碳环。5.1.9Remove the governor drive coupling.拆去调速器驱动联轴器。5.1.10Remove the overspeed bolt trip collar (A105) according to Section: 7.1按7.1程序拆去超速跳停螺栓的法兰盘（A105）。5.2Rotor replacement装转子5.2.1Verify that the interior of the turbine casing is clean and that all foreign objects have been removed.确认把机座腔体里面全部清理干净。5.2.2Clean or replace journal bearings (367), and lubricate journal area of the shaft to prevent scratching and scoring.清洁或更换径向轴承（367），并润滑轴颈位置，以免擦伤及产生刻痕。