June, 2019 - Steam Turbine Generator Failure Modes, Troubleshooting, Proven Repair Methods

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June 12 & 13, 2019 in Sophia Antipolis, France

This course is presented in partnership with TG-Advisers, Inc.

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This course provides each delegate with a detailed and applied review of the most common turbine failure modes. Our instructors will focus on risk informed repair and life extension strategies which have a significant bottom line impact. The course will also offer best practices and maintenance considerations for flexible operation which typically includes more cycling, lower minimum loads, and greater capacity ratings. All modules are supplemented with current case studies demonstrating the applied techniques. Eligible for professional certifications.

Who Should Attend?

This course is designed for plant maintenance and operations personnel, consultants, loss control engineers, equipment OEMs and central staff responsible for fossil, nuclear and combined cycle plant reliability. Ideal for those needing to complete pdh credits in 2019.

Course Syllabus

MODULE 1 – Steam Turbine Design, Failure Modes, and Advanced Troubleshooting

• Industry failure statistics-locating the areas of highest risk
• Steam turbine design features – key features for your unit and technology advancements
• Common failure modes for steam turbines –explained, impacted components, how to manage and impact of flexible operations on each failure mode

  • High Cycle Fatigue
  • Low Cycle Fatigue
  • Stress Corrosion Cracking
  • Solid Particle Erosion
  • Water Droplet Erosion
  • Creep and Embrittlement
  • Foreign Object Damage

• Advanced Troubleshooting – detecting and mitigating before manifesting into a forced outage
• Turbine vibration – unlocking the secrets of rotor lateral and torsional vibration
• Nondestructive testing – most effective nondestructive inspections to detect known failure modes
• OEM Technical Advisories/Service Bulletins – management and integration into outage scopes

MODULE 2 – Generator Reliability Improvements, Failure Modes, and Troubleshooting

• Key components and design features – overview and purpose of each components

  • Winding Insulation Types
  • Retaining Rings – 18-5 vs. 18-18
  • Hydrogen vs. Air Cooled
  • Auxiliary Equipment (exciter, grounding brushes, high voltage bushings, coolers, heaters, etc.)

• Failure modes – stator vs. rotor/field: visual and electrical signs, root causes, and mitigating actions
• Electrical testing – overview of standard electrical testing and information proved by each and acceptance criteria
• NDE techniques – Recommended techniques for retaining rings, fan blades, etc.
• Outage type – robot vs. rotor out, pros and cons of each
• Generator capability curve – how to read and importance
• Economical repair options – looseness, girth cracking, oil ingress
• Operations – operational data trending, flux probes and partial discharge monitoring

MODULE 3 – Impact of Flexible Operations on Steam turbine and Economical Repair Options

• Turbine operational audits – how to identify and avoid common operational pitfalls
• Impact of renewable energy and gas prices on steam turbine assets

  • Ultra-Minimum Load
  • Two-Shift Cycling

• Steam turbine rotor retrofits – key considerations, performance benefits, technology enhancements
• “No-brainers” to regain lost capacity – upgraded sealing technologies, blade path repairs and smoothing
• Emergent issues on combined-cycle steam turbines – unplanned findings early in unit life on both rotor and casings
• Strategies to safely reduce cold start times – benefits of steam seal preheat and modified hold speeds/times
• Material sampling and life extension assessments – fix only what is broken
• Targeted outage repairs – how to get back online with as little spend, time and risk as possible
• Repair options and considerations – casing cracking, stress corrosion cracking, rotor bow, solid particle erosion and water droplet erosion, foreign object damage
• Outage planning and risk assessments for key turbine hardware – how to optimize outage intervals based on current hardware condition

Practical Case Studies

• Blade failures and repair strategies – high-cycle fatigue, low-cycle fatigue, aeroelastic vibration, water droplet erosion and solid particle erosion
• Stress corrosion cracking and repair options
• Casing cracking
• Rotor shaft cracking
• Rotor bow repairs
• Generator boresonic inspection interval extensions
• Remaining life studies – creep, low-cycle fatigue, stress corrosion cracking


The registration fee for the course is 1400€ per person and includes all course materials, as well as a lunch each day of the course. Early-bird discount of 15% applies until 28 February, 2019.  Discount of 20% if included in the booking of a full track (five days of courses) or if any company books five or more days of courses in total for their staff.

To register or for more information, please contact Christine Vallon, or call our European office at +33 4 92 96 92 54.


About Us

Established in 1988, Tetra Engineering has more than 25 years experience providing solutions to the power industry. We specialize in solutions for HRSGs, conventional boilers & steam-cycle balance of plant.


Our Locations

Offices in: Connecticut, USA; Nice, France; Dubai, UAE.