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When installed and operated properly, general purpose steam turbines are reliable and tend to be forgotten, i.e., out of sound and out of mind. But, they can be sleeping giants that can result in major headaches if ignored. Three real steam turbine undesirable consequences that immediately come to mind are: Injury and secondary damage due to an overspeed failure. An overspeed failure on a big steam or gas turbine is one of the most frightening of industrial accidents. The high cost of an extensive overhaul due to an undetected component failure. A major steam turbine repair can cost ten or more times that of a garden variety centrifugal pump repair. Costly production loses due an extended outage if the driven pump or compressor train is unspared. The value of lost production can quickly exceed repair costs. A major goal of this book is to provide readers with detailed operating procedure aimed at reducing these risks to minimal levels. Start-ups are complicated by the fact that operators must deal with numerous start-up scenarios, such as: Commissioning a newly installed steam turbine Starting ups after a major steam turbine repair Starting up a proven steam turbine after an outage Overspeed trip testing It is not enough to simply have a set of procedures in the control room for reference. To be effective, operating procedures must be clearly written down, taught, and practiced—until they become habit.

Process machines are critical to the profitability of processes. Safe, efficient and reliable machines are required to maintain dependable manufacturing processes that can create saleable, on-spec product on time, and at the desired production rate. As the wards of process machinery, we wish to keep our equipment in serviceable condition. One of the most challenging aspects of a machinery professional or operator’s job is deciding whether an operating machine should be shut down due to a perceived problem or be allowed to keep operating. If he or she wrongly recommends a repair be conducted, the remaining useful machine life is wasted, but if he or she is right, they can save the organization from severe consequences, such as product releases, fires, costly secondary machine damage, etc. This economic balancing act is at the heart of all machinery assessments. Troubleshooting is part science and part art. Simple troubleshooting tables or decision trees are rarely effective in solving complex, real-world machine problems. For this reason, the authors want to offer a novel way to attack machinery issues that can adversely affect the reliability and efficiency of your plant processes. The methodology presented in this book is not a rigid “cook book” approach but rather a flexible and dynamic process aimed at exploring process plant machines holistically, in order uncover the true nature the problem at hand.