Repair of industrial steam turbines MAN and EKOL for Kernel

[ Year: 2025 ]

[ Country: Ukraine ]

[ Industry: Energy industry ]

Objective:

to perform maintenance and medium repair of MAN MARC2-С12 and EKOL P13.6-6.4/1.2 E steam turbines after 25,000 operating hours;
to detect defects, inspect the condition of key turbocharger components, eliminate the cause of increased vibration, and ensure stable long-term operation of the equipment.

Key Features:

works were executed at operational industrial facilities;
maintenance covered the turbine, gearbox, generator, oil system, valves, and auxiliary systems;
special attention was paid to inspecting the bearings of the turbine shaft, gearbox shaft, and generator shaft, as well as the condition of the babbitt lining;
shaft line alignment was performed: turbine – gearbox – generator;
one of the key tasks was identifying and eliminating the root cause of increased turbine vibration;
works were carried out within a tight schedule of 28 days;
the turbine was commissioned on the 26th day, ahead of schedule.

Implementation:

development of the maintenance and medium repair plan;
inspection of the main turbocharger components prior to shutdown;
pre-work shaft alignment check;
dismantling, inspection, and maintenance of the turbine stator and rotor;
measurement of operational clearances with data logging in the turbine logbook;
rotor inspection, runout check, and dynamic balancing;
overhaul of front and rear bearing pedestals;
dye penetrant testing (PT) of bearings;
inspection of the bearing babbitt condition;
maintenance of the turbocharger gearbox;
inspection of the gearbox driving and driven shafts;
alignment of the turbine, gearbox, and generator;
overhaul of the generator, inspection of the rotor, windings, insulation, cooler, and air gap;
maintenance of the stop, quick-closing, and control valves;
overhaul and maintenance of the lubrication system: oil coolers, filters, reservoirs, relief valves, and high-pressure hydraulics;
elimination of leaks in steam, water, and oil systems;
dismantling and reinstallation of thermal insulation;
I&C monitoring following the repair works;
commissioning works and 48-hour monitoring of the turbocharger operational parameters.

Result:

The root cause of the increased turbine vibration was identified and resolved. Following the repair completion, the turbocharger was successfully started on the first attempt on the 26th day of works, ahead of the planned schedule. Based on the maintenance results, the customer was provided with recommendations for further equipment operation, the next scheduled maintenance, and an overhaul after 50,000 operating hours.