steam turbine erection manual.pdf

7/31/2019 steam turbine erection manual.pdf

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E R E C T I O NM A N U A L

STEAM TURBINE500 MW

(KWU DESIGN)

DOCUMENT NO. TS-T1-08

Bharat Heavy Electricals Limited

POWER SECTORTECHNICAL SERVICES (HQ)NOIDA

Bharat Heavy Electricals LimitedRev 00, 7-98

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FOREWORD

I am glad that Power Sector - Technical Services ( Head Quarters),

Noida has brought out this erection manual of 500 MW steam

turbine (KWU design) being produced by BHEL. This manual lays

emphasis on site optimisation techniques which aims at uniform

erection practices, improvement in quality, reduction in time cycle

and saving in cost.

I am sure, this manual will form the basis for site erection activities

so that the organisation can derive full benefit out of this. It is

needless to emphasize that upgrading of technology is a continuous

process and we have to review our methods of working and make

suitable changes, wherever required.

(K P Mathur)New Delhi Executive Director(PEM & TS)


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1 TECHNICAL DATA T 1- 08-0101G

2 INSTRUCTION FOR HANDLING ANDSTORAGE OF TURBINE

T 1-08-0202G

3 ERECTION SEQUENCE T 1-08-0303G

4 ERECTION PROCEDURE T 1-08-0404G

5 GROUTING PROCEDURE T 1- 08-0505G

6 ASSEMBLY OF IP MODULE AT SITE T 1-08-0606G

7 SEALING AND ANTISEIZING COMPOUNDS T 1-08-0707G

8 CRITICAL ACTIVITIES T 1-08-0808G

9 SPRING LOADED FOUNDATION T 1- 08-0909G

10 ERECTION OF PIPING T 1-08-1010G

11 SPECIFICATION FOR GAS HEATING DEVICE T 1-08-1111G

12 SPECIFICATION FOR BREECH NUT HEATINGDEVICE

T 1-08-1212G

13 SPECIFICATION FOR THERMAL INSULATION T1-08-1313 G


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The following codification system is used for numbering of instructions and thecodification of Log Sheets is as per FQA document.

XX X - XX XX XX XAlpha Numeric Numeric Numeric Numeric Alpha

Type ofInstruction

System Instruction No

System Designation

Rating of Main Equipment

Type of Manual

Product Code

1.1 PRODUCT CODE

B Boiler

BA Boiler Aux.

T Turbine

TA Turbine Aux.

G Generator

GA Generator Aux

P Power Plant Piping

CI C&I

1.2 TYPE OF MANUAL

1 Erection

2 Commissioning

3 Service


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1.3 RATING OF MAIN EQUIPMENT

01 200/210 MW

02 120 MW

03 110 MW

04 60 MW

05 30 MW

06 100 MW

07 235 MW

08 500 MW KWU Design



11 60 MW KWU Design

12 70 MW KWU Design

13 Industrial Units

14 210 MW Tower Type Concrete Pylem

15 210 MW Tower Type Steel Structure

16 500 MW Tower Type Once through

17 250 MW

18 CCP


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1.4 SYSTEM DESIGNATION

SNO DESCRIPTION

1. TECHNICAL DATA

2. INSTRUCTION FOR HANDLING AND STORAGEOF TURBINE

3. ERECTION SEQUENCE

4. ERECTION PROCEDURE

5. GROUTING PROCEDURE

6. ASSEMBLY OF IP MODULE AT SITE

7. SEALING AND ANTISEIZING COMPOUNDS

8. CRITICAL ACTIVITIES

9. SPRING LOADED FOUNDATION

10. ERECTION OF PIPING

11. SPECIFICATION FOR GAS HEATING DEVICE

12. SPECIFICATION FOR BREECH NUT HEATINGDEVICE

13. SPECIFICATION FOR THERMAL INSULATION

1.5 TYPE OF INSTRUCTION

G General

T Technical

L Log Sheet

C Check List


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LOAD

RATED 500 MW

MAX. UNDER VALVE WIDE OPEN (VWO) CONDITION 524.2

CONSTRUCTION

THREE CYLINDER REHEAT CONDENSING TURBINE 500 MW

SINGLE FLOW HP TURBINE WITH 17 REACTION STAGES TYPE H30-100-2

DOUBLE FLOW IP TURBINE WITH 12 REACTION STAGES PERFLOW

TYPE M30-63

DOUBLE FLOW LP TURBINE WITH 6 REACTION STAGES PERFLOW

TYPE N30-2X10

2 MAIN STOP AND CONTROL VALVES TYPE EV320-1

2 REHEAT STOP AND CONTROL VALVES TYPE IV560

1 SWING CHECK VALVE IN COLD REHEAT LINEMAKE

DN-800BHEL,TIRUCHY

2 BYPASS STOP AND CONTROL VALVES DN-320

EXTRACTION SWING CHECK VALVES :

EXTRACTION-1 : NO VALVE -

EXTRACTION-2 : 1 SWING CHECK VALVE WITH ACTUATORMAKE

DN-800BHEL,TIRUCHY

EXTRACTION-3 : 1 SWING CHECK VALVE WITH ACTUATOR&1 SWING CHECK VALVE WITHOUTACTUATOR

MAKEDN-500

BHEL,TIRUCHY

EXTRACTION-4.1 : 2 SWING CHECK VALVE WITH ACTUATORMAKE

DN-500BHEL,TIRUCHY

EXTRACTION-4.2 : 2 SWING CHECK VALVE WITH ACTUATORMAKE

DN-500BHEL,TIRUCHY

EXTRACTION-5 : 1 SWING CHECK VALVE WITH ACTUATOR&1 SWING CHECK VALVE WITHOUT ACTUATOR

MAKEDN-400

BHEL,TIRUCHY

EXTRACTION-6 : NO VALVE

SPEED

RATED SPEED 50.0 /S


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SPEED LIMITATION IN LOAD & STATION AUX. LOADOPERATION

MAX. SPEED, NO TIME LIMITATIONMIN. SPEED, NO TIME LIMITATION

PERMISSIBLE FOR A MAXIMUM OF 2 HRS. DURING THE LIFE OF

LP BLADING SPEEDBELOW

SPEEDABOVE

::

:

:

524.251.5 /S47.5 /S

47.5 /S

51.5 TO 60 /S

SPEED EXECUTION RANGE AT OPERATION WITHOUT LOAD* : 6.7 TO 47.5 /S

STANDARD OVER SPEED TRIP SETTING : MAX. 55.5 /s

* THIS SPEED RANGE SHOULD BE PASSED THROUGH IN ONE

SMOOTH OPERATION TO AVOID ENDANGERING THEBLADES DUE TO RESONANCE

STEAM PRESSURES

RATED* LONG TIMEOPERATION

SHORT TIMEOPERATION

INITIAL STEAM 166.7 166.7 20.7 BAR

BEFORE 1st HP DRUM STAGE 154.4 163.4 169.9 BAR

HP CYLINDER EXHAUST 44.9 52.0 57.4** BAR

IP CYLINDER STOP VALVE INLET 40.3 46.7 55.2** BAR

EXTRACTION 6 44.9 52.0 57.4 BAR






LP CYLINDER EXHAUST 0.1013 0.3 0.3 BAR

* THESE VALUES CORRESPOND TO 500 MW LOAD WITH 3% MAKE-UP AND 0.1013 BAR BACKPRESSURE WITH ALL HEATERS IN SERVICE AND RATED STEAM CONDITIONS.

** THE SAFETY VALVES MUST BE SET SO THAT THESE SHORT TIME VALUES ARE NOT EXCEEDED.

LONG TIME OPERATION : UPPER LIMIT VALUE, PERMISSIBLE WITHOUT TIME LIMIT.

SHORT TIME OPERATION : PERMISSIBLE MOMENTARY VALUE. THE AGGREGATE DURATION OFSUCH SWINGS MUST NOT EXCEED 12 HOURS IN ANY ONE YEAR.

ALL PRESSURES ARE ABSOLUTE PRESSURES


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LOW VACUUM TRIP, STANDARD SETTING

HYDRAULIC LOW VACUUM TRIP : 0.3 BAR

ELECTRICAL LOW VACUUM TRIP : 0.3 BAR

HYDRAULIC LOW VACUUM TRIP BYPASS OPERATION : 0.6 BAR

SEAL STEAM SUPPLY SYSTEM

PRESSURE IN SEAL STEAM HEADER (ABOVE ATMOSPHERIC) : 35 MBAR

AXIAL SHIFT

ALARM TRIP

* 0.5 mm * 1 mm

* DIRECTION OF ROTATIONANTI CLOCK WISE WHEN VIEWED FROM FRONT PEDESTAL TOWARDS THEGENERATOR


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STEAM TEMPERATURES

RATED

VAL.ANNUAL

MEAN

VALUE

LONG TIME

VALUE(WITHINANNUAL

MEANVAL.)

400 h

PERANNUM

80 h PER

ANNUMMAX. 15

MIN IN

INDIVIDUAL CASE

INITIAL STEAM 536.0 546.O 552.O 566.0OC

IP CYLINDER STOP VALVE INLET 536.0 546.3 552.0 566.0OC

RATEDVALVE *

LONGTIME

OPERATI

ON

80 h PERANNUM

MAX. 15

MIN ININDIVIDUAL CASE

INSPECIALCASES

AT NOLOAD

HP CYLINDER EXHAUST 340.0 360.0 440.0 500.0**OC

EXTRACTION 6 340.0 360.0 440.0 500.0**OC

EXTRACTION 5 413.9 421.9 459.9OC

EXTRACTION 4 292.1 304.1 346.4OC

EXTRACTION 3 187.3 195.3 242.3OC

EXTRACTION 2 128.3 139.3 184.3OC

EXTRACTION 1 66.5 86.5 136.5OC

LP CYLINDER EXHAUST 46.1 70.0 70.0OC

LONG TIME OPERATION : UPPER LIMIT VALUE, PERMISSIBLE WITHOUT TIMELIMIT.

* THESE VALUES CORRESPOND TO 500 MW LOAD WITH 3% MAKE-UP AND 0.1013 BARBACK PRESSURE WITH ALL HEATERS IN SERVICE AND RATED STEAM

CONDITIONS.

** ONLY VALID FOR THE NO LOAD PERIOD WITH HIGH REHEAT PRESSURE AFTERTRIP-OUT FROM FULL LOAD OPERATION. FOR INDIVIDUAL CASE APPROX. 15MINUTES

THE TURBINE IS IMMEDIATELY RE-LOADED OR THE BOILER IMMEDIATELYREDUCED TO MINIMUM LOAD IF NO LOAD OPERATION IS MAINTAINED.


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CASING TEMPERATURES

WALL TEMPERATURES ALARMAT

MACHINE MUST BESHUT DOWN AT

HP TURBINE CASING EXHAUST 480 500OC

OUTER CASING OF LP CYLINDER 90 110OC

PERMISSIBLE DIFFERENTIAL TEMP. BETWEEN PARALLEL STEAM SUPPLY LINES :

NO TIME LIMITATION : 17OC

SHORT TIME PERIOD (15 MIN.) : 28OC

IN THE HOTTEST LINE THE LIMITATIONS INDICATED FOR INITIAL STEAM & REHEAT TEMP. MUST NOT BE EXCEEDED.

SPRAY WATER TO LP TURBINE MUST BE SWITCHED ON AT 90O

C.

TEMPERATURES DIFFERENCE ALARMAT

MACHINE MUST BE

SHUT DOWN AT

DIFFERENCE BETWEEN UPPER & LOWERCASING HALVES HP TURBINE. MIDDLE

* 90 * 100 OC

LP TURBINE. FRONT * 30 * 45OC

LP TURBINE. REAR * 30 * 45OC

FEEDWATER HEATER OUT OF SERVICE

OPERATION WITH FEEDWATER HEATER OUT OF SERVICE MAIN STEAMFLOW Kg/s

LOADMW

EXTRACTION A6 = 0 395 500





EXTRACTION A6, A5 = 0 400 525

OUTPUT LIMIT DURING TESTING WITH AUTOMATIC TURBINE TESTER

TESTING OF MAIN STEAM STOP & CONTROL VALVE 400 M W

TESTING OF HRH STEAM STOP & CONTROL VALVE 200 - 500 M W

MOTORING :

MOTORING IS THE CONDITION IN WHICH THE TURBINE IS DRIVEN BY THE GENERATOR ATRATED SPEED WITH THE STOP & CONTROL VALVES CLOSED. IN THIS OPERATING MODE,CERTAIN TURBINE COMPONENTS ARE HEATED UP BY WINDAGE POWER IN THE BLADING.TO PREVENT HEAT-UP BEYOND PERMISSIBLE TEMPERATURES, MOTORING MUST NOT BEALLOWED TO CONTINUE FOR LONGER THAN ONE MINUTE. IF THE CONDENSER LOWVACUUM LIMIT OF 0.3 BAR IS EXCEEDED, MOTORING MUST NOT BE ALLOWED TO CONTINUEFOR MORE THAN 4 SECONDS.


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OIL SUPPLY

MAIN OIL TANK, RATED CAPACITY : 25/40 Cu . M

Ist OIL FILLING (ESTIMATED) : 47.5 Cu . M

FLUSHING OIL QUANTITY (ESTIMATED) : 28.5 Cu . M

OIL COOLER FOR OPERATION, NUMBER : 1 NO.

OIL COOLER FOR RESERVE, NUMBER : I NO.

OIL TEMP. AT COOLER OUTLET, UNIT IN OPERATION

MIN.NORMALMAX.

:::

384547

OC

OIL TEMP. AT COOLER OUTLET, UNIT SHUT DOWN

MAX. : 75OC

TEMP. RISE OF OIL IN BEARINGSNORMAL

MAX.

::

2025

OC

ESTIMATED OIL REQUIREMENTS OF BEARINGS :

BEARING 1(HP TURBINE, FRONT PEDESTAL) : 0.8 dm3/S

BEARING 2 : 15.4 dm3/S



GENERATOR FRONT BEARING : 7.92 dm3/S

GENERATOR REAR BEARING : 7.92 dm3/S

EXCITER BEARING : 0.70 dm3/S

1 DUPLEX OIL FILTER FOR BEARING OIL (FULL FLOW) : 200 mm

DUPLEX OIL FILTER . TYPE - 2.62.9. SIZE 355/750. MAKE : BOLL & KIRCH

FILTRATION PARTICLE SIZE OF DUPLEX FILTER ELEMENT : 37 m

FILTRATION PARTICLE SIZE OF MAIN OIL TANK FILTER

ELEMENT

: 250 m

SAFETY VALVE IN JACKING OIL SYSTEM, SETTING

MAX.

: 200 BAR

PRESSURE LIMITING VALVE IN JACKING OIL SYSTEM,SETTING

: 100 BAR

1 DUPLEX OIL FILTER FOR JACKING OIL : 25 mm

FILTRATION PARTICLE SIZE OF JACKING OIL FILTER : 37 m


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OIL PUMPS

MAIN OILPUMP

AUXILIARYOIL PUMP

DCEMERGENCY

OIL PUMP

JACKINGOIL PUMP

QUANTITY 1 2 1 AC : 2 DC : 1

MAKER BHEL KSB KSB TUSHAKO

TYPE 97.22 dm3/S ETA-150-

50VVLETA-100-

33VVLSDF80

CAPACITY

(RATED)

75 89.25 30 1.53 dm3/s

DISCHARGE

PRESSURE(GAUGE)

8.6 6.2 2.3 178 BAR

SPEED 50 24.75 24.3 49.42 /s

DRIVE TURBINE AC MOTOR DC MOTOR ACMOTOR

DCMOTOR


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CONTROL FLUID SUPPLY

CONTROL FLUID TANK, RATED CAPACITY : 10/16 Cu . M

Ist FLUID FILLING (ESTIMATED) : 15 Cu . M

FLUSHING FLUID QUANTITY (ESTIMATED) : 10 Cu . M

CONTROL FLUID COOLER FOR OPERATION, NUMBER : 1 NO.

CONTROL FLUID COOLER FOR RESERVE, NUMBER : I NO.

CONTROL FLUID MAINTENANCE EQUIPMENT :

GEAR PUMPMANUFACTURER

TYPE

::

STEIMELBGK 2-24R

FLUID FLOW : 0.28 dm3/S

GAUGE PRESSURE : 3.06 at

SPEED : 25 S-1

MOTOR POWER : 0.75 KW

2 EARTH FILTERS

MANUFACTURERTYPE

::

ROTRINGPYG5-350

EARTH FILLING MESH : 140 Kg

1 FINE MESH FILTERMANUFACTURER

TYPE

::

ROTRINGS-1800-14-TUY

FILTRATION PARTICLE SIZE : 3-5 m

FILTER MATERIAL : COTTON

CONTROL FLUID SUPPLY SYSTEM

A FIRE RESISTANT FLUID IS USED FOR THE CONTROL SYSTEM

SCOPE

The document covers all steam turbine components and provides the handling,inspection and storage instructions for large steam turbine components at site.A strict adherence to these instructions is necessary to avoid damages duringhandling and storage at site.


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HANDLING OF EQUIPMENT :

In any kind of rigging work it is necessary to strictly observe the safety precautions,since even the slightest negligence and non observance of the rules may result

in accidents, which may cause damage to equipment or injury to men.

The site for the rigging work involving lifting and conveying of loads should be welllighted. The loads must not be lifted unless the crane operator can see clearlythe signals given by the rigger.

The positions where the slings are to be put, are marked on the packages and onthe drawings. While lifting/handling these packages/equipment, the slingsshould only be put at the proper places.

The slings of the proper sizes and lengths should only be used for handling theequipment/packages. The angle between the two arms of the sling at the

crane hook should be small (depending upon the dia of the sling) so as to haveproper loading of the sling.

The turbine rotors and cylinder covers (in assembled condition are lifted by theuse of special lifting devices supplied by BHEL. The use of these liftingdevices facilitates correct slinging and maintain horizontal position of thecomponents. These devices, after use, should be properly stored andconserved so as to ensure that they do not get damaged during storage.Before using them, they should be thoroughly inspected.

The work related to handling of the loads (packages or equipment) by crane or byother hoisting mechanism should be entrusted to trained riggers only. If

the rigger/operator is not sure of the weight of the item/package (load) tobe handled, he must ask for the required information before handling theequipment.

The rigger and the crane operator should see that the hook and the ropes of thecrane occupy vertical position, before hoisting the load. Dragging of the loadby slanting ropes is not allowed. The center of gravity of the load should bealigned with the vertical axis of the crane hook.

The eye bolts, 'D' shackles, turn buckles, and wire ropes of suitable sizes shouldonly be used for handling of the equipment. Before using, they should be

thoroughly inspected to their full threads, so as to avoid any chance ofslipping then the load comes on them.

Before giving a signal to lift the load, the rigger must check and ensure that there areno loose parts or tools on the load, which might fall during lifting. Then the loadmust be lifted 100 or 200 mm high for checking the uniformity of slingtensioning and reliability of lashing. If it is necessary to rearrange the slinglengths, the load must be lowered and then the slings rearranged.

Before horizontal conveyance of the load the rigger must see that the load has beenlifted to a height at least 0.5 M above the tallest object, on the path of the load.


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While the load is being conveyed, the rigger must accompany it and seethat it is not moved above any person. Prior to lowering the load the riggershould examine the ground on which the load will be, lowered and make surethat these is no risk of falling or slipping of the load.

If any one of the personnel present during lifting or lowering of the load detects some

defect of the crane or sling of notices some conditions jeopardizing the lifting orlowering operation, he must give a signal for emergency grounding of thepackage or components.

Smooth lifting and transportation of equipment must be ensured. Shocks and jerksshould be avoided.

All lifting devices, slings must be properly conserved after use and periodicallyinspected and tested.

In the turbines having diaphragms, it is prohibited to handle diaphragms by puttingslings in between the blades. For handling the welded diaphragms, special

lifting devices is supplied by BHEL and the cast diaphragms are handledby putting the eye bolts, for which the provision of threads holes have beenmade in the diaphragms.

While handling the bearings, it is prohibited to put the sling across the rabbit surface ofthe bearings. Threaded holes have been provided; in which the eye bolts haveto be put for handling of the bearings.

While handling the cylinders, it must be ensured that the slings or any other materialdoes not get rubbed at their horizontal and vertical parting planes or at anyother machined surface.

The handling of the long components such as longitudinal girder, endwall etc. shouldbe done with extra care. When they are placed on the floor, in addition to theend supports, few extra supports at the intermediate positions must be provided.

While handling LP rotor with free standing blades, care must be taken to ensure that noforce is exerted on the free standing blades to avoid collapsing of clampingpieces under blade root.

MARKINGS ON PACKING CASES

Various symbols are marked on the packing cases as per 0456.001 to facilitatestorage and handling of the crates and protection of equipment inside.

INSPECTION

Before storing the equipment it should be opened for visual examination or theinternal packing, protective coating and condition of the equipment. Anydamage to packing and conservation should be immediately rectified.

It is necessary to carryout first inspection within three weeks of arrival of theconsignment. Thereafter, all the equipment should be inspected once in everythree months to insure that the conservation is intact. During rainy season, theinspection should be done once in a month. At any time, if any original


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conservation is found damaged, it should be reconserved as per relevantconservation instructions No. ST 33004.

While inspecting the packages containing rotors, special care should be taken to checkthe journals. In case of slightest sign of pitting on the journals and thrustcollar, immediate steps for rectification should be taken and equipment

reconserved as per relevant conservation instructions.

STORAGE

All steam turbine equipment should be accommodated in the designated place ofstorage immediately after arrival at destination. This is very essential particularlyduring the rainy season.

Store houses fall into the following categories

TYPE OF CONDITIONSSTOREHOUSE

TEMP. RELATIVEHUMIDITY

ARRANGEMENT

'P' +50 Cto

500 C

< 70 % Totally enclosed, rain proof, ventilatedand dry with cemented floor.

'Q' upto500 C

- Roofed area with walls (of brick /asbestos/ GI sheet ) around and

cemented / pucca hard floor.

'R' - - Raised platform with shed of asbestos /GI sheet / water proof tarapaulin.

'S' - - Raised Platform.


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The platforms and store-houses should be built up in conformity with the fireprevention rules and standards. Complete storage area especially the R & Scatagory must be adequately fenced & protected against theft & pilferage.

These store houses and areas around them should have proper drainage facility forthe sub-soil, surface and rain water. The water should not be allowed to stand

or get accumulated in these areas, especially where the material has beenstored.

Store house should be provided with proper ventilation facilities.

Level should be maintained for all the packages and equipment and should beuniformly supported to avoid distortion. The long packages should besupported at intermediate places also, so as to avoid sagging during storage.

Store houses should preferably be equipped with proper lifting devices to ensurenormal handling of equipment.

Small and medium size parts can be kept on shelves with proper identification tags.

Packages upto 5 tones can be placed on upon the other upto 2.5m in height usingrequired number of wooden spacers 50 mm thick. In doing so, lighterpackages would be laid upon heavier once to avoid any damage to lowerpackages.

Articles weighing more than 5 tones should be laid in a single tier.

For heavier components under Q, the roof/walls may be constructed/fabricated afterplacement of the component on cemented/pucca hard floor.


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STORAGE OF STEAM TURBINE COMPONENTS

SNO. DESCRIPTION OF THE COMPONENT TYPE OFSTORAGE

1. FOUNDATION BOLT Q

2. EMBEDDED PARTS (ADDITIONAL) R

3. COMPONENTS OF BASE PLATE ASSLY. Q

4. BASE PLATE LP CASING R

5. LP OUTER CASIONG R

6. LONGITUDINAL GIRDER (LEFT & RIGHT) R

7. LP FRONT WALL (TS&GS) R

8. LP SHAFT SEALING (FRONT & REAR) Q

9. AUXILIARIES OF TURBINE Q

10. HP/IP BEARING PEDESTAL Q

11. HP/IP BEARING PEDESTAL ASSEMBLY PARTS Q

12. IP/LP PEDESTAL ASSEMBLY Q

13. LP/GEN. PEDESTAL Q

14. BEARING PEDESTAL PARTS Q

15. FRONT BEARING PEDESTAL Q

16. LIFTING BEAM R

17. LP CASING EXTRACTION A1 R

18. LP EXTRACTION A2 R

19. LP EXTRACTION A3 R

20. LP EXTRACTION PIPE SHEATHING R

21. INNER GUIDE PLATE DIFFUSER R

22. DIFFUSER (UPPER & LOWER HALVES) R

23. LP INNER-OUTER CASING (VH) Q

24. LP INNER CASING ASSEMBLY (LH & VH) Q

25. HEATING DEVICE Q

26. LP CASING ASSEMBLY Q

27. LP INNER CASING ASSEMBLY (FASTENER) Q

28. INNER GUIDE PLATE DIFFUSER (GS) R

29. LP ROTOR Q

30. IP TURBINE Q


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31. IP TURBINE PARTS Q

32. IP INLET PIPES Q

33. HP TURBINE Q

34. HP INLET ASSEMBLY Q

35. HP EXHAUST ELBOW Q

36. HPT RELATED PARTS Q

37. FRAME FOR SUSPENSION (ESV) R

38. SUSPENSION OF VALVE (ESV) Q

39. ESV & CV CASING WITH VALVE Q

40. ESV SERVOMOTORS WITH LIMIT SWITCH Q

41. HP CONTROL VALVE SERVOMOTORS Q

42. SUSPENSION OF VALVE (IV) Q

43. IV & CV CASING WITH VALVE Q

44. IV SERVOMOTORS WITH LIMIT SWITCH Q

45. IP CONTROL VALVE SERVOMOTORS Q

46. FRAME FOR SUSPENSION (IV) R

47. IV SERVOMOTORS WITH LIMIT SWITCH Q

48. STEAM BLOWING & HYD. TEST DEVICE Q

49. TOOLS FOR GOVERNING SYSTEM Q

50. SUSPENSION OF LPB VALVE Q

51. WATER INJECTION VALVES Q

52. CHEST LPB WITH STOP & CONTROL VALVE q

53. LPB STOP VALVE SERVOMOTOR Q

54. LPB CONTROL VALVES SERVOMOTORS Q

55. INJR. FOR SUCTION PIPE NB 350 R

56. INJR. FOR SUCTION PIPE NB 300 R

57. MAIN OIL TANK R

58. MAIN OIL TANK & NOZZLE ASSEMBLY R

59. OIL STRAINER Q

60. LEVEL MONITOR INSTALLATION Q

61. INSTRUMENTS Q

62. LEAKAGE / DIRTY FLUID TANK R

63. VARIABLE ORIFICES & THROTTLE Q


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64. CONTROL FLUID TANK R

65. CONTROL FLUID TANK NOZZLE ARRANGEMENT R

66. EXPANSION TANK R

67. FILTER & PR. DAMPING DEVICES Q

68. CROSS AROUND PIPE R

69. SUPPORT FOR CAP R

70. CHANGE OVER VALVE R

71. RATING & MONOGRAM PLATES Q

72. OIL STRIPER R

73. HOUSING FOR HRH STEAM STRAINER R

74. HOUSING FOR MAIN STEAM STRAINER R

75. MS & HRH STR.HSG GASKET Q

76. STEAM STRAINER MS Q

77. STEAM STRAINER HRH Q

78. COMPENSATOR Q

79. TURBINE CONTROL LPB / SUPPLY RACK Q

80. TEMPERATURE & PRESSURE CONNECTIONS Q

81. PR. TRANSMITTERS BAR. PROBES THERMOCOUPLES Q

82. TRANSMITTERS & JUNCTION BOXES Q


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STORAGE & PRESERVATION OF COMPONENTS OFTURBOGENERATOR, EXCITER AND SYSTEMS


1. EMBEDDED PARTS R

2. FOUNDATION PARTS R

3. WOUND STATOR WITH GAS COOLERS Q

4. TURNION FOOT PLATES Q

5. ROTOR Q

6. ASSEMBLY OF PIPE CONTROL FOR GAS COOLERS R

7. END SHIELDS Q

8. FAN SHIELD, GEN VVIEW HEADER ASSEMBLY R

9. TERMINAL BUSHING AND HEADER ASSEMBLY Q

10. BEARING WITH BRUSH GEAR Q

11. SEAL BODY Q12. TEMP. CONNECTION Q

13. CASING FOR TURNIONS R

14. ERECTION MATERIALS Q

15. ERECTION DEVICES R

16. SHAFT SEALS Q

17. SEAL RINGS Q

18. ADOPTING RING Q

19. AUXILIARY BEARING Q

20. CENTRIFUGAL FAN Q

21. CARBON DIOXIDE VAPOURISER Q

22. FILTER O.C.P. Q

23. EXPANSION TANK R

24. OIL SEPARATOR R

25. PRE CHAMBER R

26. S.O.S.T. R

27. SEAL OIL UNIT Q

28. HYDROGEN DISTRIBUTION R

29. CARBON DIOXIDE DISTRIBUTION R

30. VALVES FOR AUXILIARY SYSTEMS P

31. GAS UNITS Q

32. FLEXIBLE LEADS Q

STORAGE & PRESERVATION OF COMPONENTS OFHEAT EXCHANGERS


PRODUCT : CONDENSER


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1. BOTTOM PLATE S

2. LOWER DOM WALL S

3. SIDE WALL S

4. WATER CHAMBER Q

5. UPPER DOM WALL S

6. STIFFENING PIPES S7. STIFFENING RODS S

8. TUBE SUPPORT PLATE R

9. WATER BOX R

10. AIR EXTRACTION PIPING R

11. HOTWELL S

12. SPRING ELEMENTS R

13. LOOSE ITEMS Q

14. INSTRUMENTS Q

15. CONDENSER TUBES (STAINLESS STEEL) R

16. CONDENSER TUBES (NON-FERROUS) Q

17. VACUUM PUMP Q18. EJECTOR R

19. AIR MEASURING DEVICE Q

PRODUCT : HEATER

1. GLAND STEAM CONDENSER R

2. STAND PIPE Q

3. INSTRUMENTS Q

4. DRAIN COOLER R

5. L.P.HEATERS R

PRODUCT : COOLER1. OIL COOLER R

2. CONTROL FLUID COOLER R

3. STATOR WATER COOLER R

4. HYDROGEN COOLER Q

5. EXCITER AIR COOLER Q

6. INSTRUMENTS / LOOSE ITEM Q


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MAXIMUM PERMISSIBLE LOADING FOR WIRE ROPES IN KG.

NOMINAL SINGLE DOUBLE CORD WITH INCLUDED ANGLE OFDIA (d) OF

ROPES mm

CORD

0o

45o

90o

120o

9 522 1044 965 738 522

12 1170 2340 2070 1580 1170

18 2150 4300 4000 3060 2150

24 3850 7700 2100 5400 3850

30 6200 12400 11500 8800 6200

36 9000 18000 16600 12700 9000

42 12200 24400 22600 17300 12200

48 16000 32000 29500 22600 16000

54 20200 40400 37300 28500 20200

60 24900 49800 46000 35200 24900

66 30100 60200 55700 42600 30100

72 35800 71600 66200 50700 35800

78 42100 84200 77700 59500 42100

84 48800 97600 90200 69000 48800

90 56000 112000 103500 79200 56000

96 63700 127400 117700 90000 63700

102 71900 143800 132900 101700 71900

108 81000 162000 149700 114500 81000

114 89900 179800 166100 127100 89900

120 99700 199400 184300 141100 99700


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ERECTION SEQUENCE

(For 500 MW Fixed pedestal type Turbine with spring loaded foundation)

1. Cleaning and checking of Turbine and Generator foundations as per the transverse

and longitudinal axis including their elevation.

2. Prepare and install LP base plates, HP front pedestal, HP rear pedestal, LP front

pedestal, LP rear pedestal along with their anchor bolts and anchor plates.

3. Provisionally align and level all the pedestal and LP base plates as per the

transverse and longitudinal axis including their elevation.

4. Matching of anchor plates of pedestal and LP base plates to ensure their perfect

seating.

5. Finally align and level HP front, HP rear, LP front and LP rear pedestals along with

LP base plates as per the transverse and longitudinal axis including their elevation

and catenary as per the design.

6. Prepare and install steel bars for LP casing centralising keys in foundation slab as

per the required center line .

7. Weld locating ring of LP front pedestal and steel bars of LP front and LP rear

centralising keys.

8. Prepare shuttering and grouting of the pedestals and LP base plates including

anchor plates of HP rear pedestal.

9. Prepare, install, align/ level both the LP girder along with their carrier plates.

10. Prepare , install and assemble LP front and rear end walls with the LP girders.

11. Level / align LP outer casing lower half as per the transverse and longitudinal axis

of the machine.

12. Install permanent packers of LP outer casing including their radial and axial keys.

13. Prepare and install LP inner outer casing along with gusset plates in position


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14. Align LP inner outer casing lower half and level it. Install LP casing parting plane

platform .

15. Prepare and install LP front and LP rear lower half shaft seals housing and align it

provisionally.

16. Prepare and install LP rotor along with their bellows in position.

17. Align LP rotor radially and axially in position and record free run out of rotor.

18. Record/ Ensure radial and axial clearances of the LP casing including rotor float

including fitting of final axial keys of the LP inner casing .

19. Box up LP inner inner casing and heat tighten the parting plane bolts.

20. Box up LP inner outer casing .

21. Prepare and place HP module in position on temporary packers.

22. Transfer the load of HP rotor on bearings from the transport device and align it

radially and axially.

23. Check free run out of HP rotor on journal and coupling face including its float.

24. Prepare and place IP module in position on temporary packers. (In case IP module

is sent to site in disassembled condition, refer Instruction T1-08-0606G.

25. Loading of IP rear end of the shaft on bearing and removal of transport device.

26. Provisionally align HP , IP and LP rotor .

27. Couple HP / IP rotor on temporary Bolts and align rotor / casing radially and axially.

28. Record/ Ensure IP rotor float by shifting HP casing axially.

29. Conduct Horn drop test of HP casing without any radial and axial keys and pipe

lines.

30. Conduct Horn drop test of IP casing without IP inlet upper half pipe lines.

31. Assembly of breech nut of HP casing and Main Steam Stop & Control valve

assembly.


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32. Erection of Reheat Stop & Control valve assembly.

33. Weld IP inlet upper half pipe and record Horn drop values without radial-axial keys.

34. Alignment of HP/IP/LP rotors and their coupling on temporary bolts including its

couple runout.

35. Swing check of HP rotor on its front end with temporary alternate bolt tightened on

HP/IP coupling .

36. MOP alignment and its doweling.

37. Reaming/honing of HP/IP and LP/IP coupling including fitting of final coupling bolts.

38. Fixing of axial position of shaft and assembly of thrust bearing including its colour

matching.

39. Roll check of HP/IP casing and fixing of radial and axial keys of the casing (Casing

final packers need not to be put at this stage).

40. Assembly of bearings and checking of all clearances including fittings of side pads

of bearing, yoke keys etc.

41. Turbovisory works in all the pedestal i.e. assembly and calibration of thrust bearing

axial shift, LP rotor expansions pick up, Hall generator and thermocouples of

bearing .

42. Preparations of the bearing for oil flushing.

43. Oil flushing of the machine and normalizing the bearing after oil flushing.

44. Preparation and floating of TG deck as per Instruction No. T1-08-0909G.

45. Decoupling of HP / IP, LP/IP, LP/Gen., Gen./Exciter coupling and rechecking of

alignment/catenary after floating of TG deck spring.

46. Final tightening of HP/IP, IP/LP , LP/Generator and Generator / Exciter coupling

after correcting the alignment including their couple run out and swing check of rotor

on HP Front and exciter rotor.


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47. Checking /Correction of LP shaft seal clearance after floating of TG deck with CW

pump in operation and water in the hot well of condenser upto operating level.

48. Roll check of HP, IP casing in up and down direction only with TG deck in floating

condition and CW pump in operation including water in hot well upto normal level.

49. Assembly of final packers of the HP, IP casing after completing the roll check in up

and down direction.

50. Recording of final Horn drop of HP and IP casing after completing the welding of

HP inlet, HP exhaust , IP inlet and Cross around piping.

51. Preparation and boxing up of LP casing after competing the full Roll check of LP

casing and fitting of final casing packers and radial keys.

52. Barring gear.


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CHECKING OF FOUNDATION BEFORE CASTING

Customer to provide, center line and elevation point.

Check positioning of all the inserts and fixed points with respect to center line

in transverse and longitudinal direction as per BHEL Hardwar drawings.Check elevation of all points.

Check verticality of all the pipe sleeves with the help of plumb.

Ensure proper locking of all the insert and fixed points before grouting.

Ensure leveling on the fixed points of LP girder and LP rear pedestal.

Preserve machined surfaces of all the fixed points against any damages due toImproper handling.

Ensure proper flatness of the bottom seating plate of all the inserts.

Ensure proper stiffeners in all the vertical and horizontal embedment providedfor various purposes like hangers and supports etc.

Ensure proper cleaning of the area before casting.

Remove all unwanted material.

NOTE: In case of spring loaded TG deck refer Installation InstructionNo. T1-08-0909G prior to positioning of inserts etc.

CHECKS DURING CASTING/POURING OF CONCRETECasting of foundation\TG deck should be carried out immediately after

inspection of the foundation\TG deck i.e. within 3-4 days after finalinspection to avoid any disturbance to the inserts and fixed point.

Ensure no disturbance to the insert etc. during pouring of concrete whilevibrators are used.


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About 15-20 mm extra concrete may be left on top on all the pedestals and LPbase plate area for chipping/cleaning purpose at a later date.

Close all the pipe sleeve from top to avoid entry of concrete inside. Alternatelythe pipe sleeve should be filled with sand.

CHECKING OF FOUNDATION AFTER CASTING

Clean complete foundation and remove all shuttering etc.

Ensure there is no loose concrete layer in the region where the pedestal andbase plates are to be laid. No repair should be done in this region withoutconsulting the turbine erection engineer.

Cover all the opening before checking any dimensional measurement toavoid any accident.

Establish a suitable longitudinal axis considering the fixed point of the LP rear

pedestal and various pipe sleeves / inserts.

Establish a transverse axis as 90 degree with the help of the odolite.

Measure pitching/elevation of all the inserts and fixed points.

Measure elevation of all foundation on different pedestal and LP base plate area.

Check level of LP rear pedestal fixed points and if required correction maybe carried out.

PREPARATION OF FOUNDATION FOR PLACEMENT OFPEDESTALS AND BASE PLATES:

Foundation are to be cleaned and loose concrete are to be chipped off.

Maintain elevation of foundation to ensure correct thickness of non-shrinkgrout.

A reference point for elevation in respect of machine center line (equivalent to LPrear pedestal) is to be maintained at a proper place. This point is to bepreserved with proper protection. For making reference point a one sideground plate of about 200 x300 x20 mm may be used. This may bewelded on a I-beam near Generator. The ground position of the plate isto be kept on top side and all elevation are to be transferred from thispoint with the help of water level jar. A correct elevation reading is tobe punched on this plate. This reference point is to be used only during theturbine erection period.

Clean and deburr piping sleeves of the foundation on ID/OD of the pipe.

Ensure all corners of the foundation remains perfect during chipping of extraconcrete of foundation.


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Check contact between spherical Torus piece of bearing andspherical/cylindrical seat. In case of any variation in contact noscraping/cutting to be carried out at site and this may be referred tomanufacturing unit. Also refer T1-08-0808G. Check centering of individualbearing w.r.t. pedestal seal bores by fixing pianowire on individual

pedestal.

Ensure cleanliness of all pedestal oil lines. Close opening of oil lines ofpedestal to avoid any foreign material entering in these pipe lines duringerection at site.

Weld MOP suction and discharge pipe lines in HP front pedestal as per thedrawing before placement.

Assemble protection sheet in the foundation bolt holes of pedestals.

Assemble anchor bolts along with anchor plate of the pedestals. Ensure that

there is good contact available to the backing plate with thefoundation. If required colour matching/grinding may be carried out toachieve the contact.

Assemble protection sheet in the anchor bolt hole from bottom side of HP rearpedestal foundation to avoid entry of grout metal.

Ensure level of both anchor plate of H.P. rear pedestal with 70-90 mm gap forfilling of grouting concrete.

Adjust height of the Anchor Bolts as specified in the drawing.

PLACEMENT OF LP BASE PLATE, OVER THE FOUNDATION :Clean all the four base plates.

Mark/punch center line on the base plate as per drawing.

Ensure proper cleaning of base plate on bottom side.

Put identification marks on each base plate to avoid any mistake in positioning ofthe same.

Do colour matching of all the eight nos. carrier plate on both the faces.

Match LP base plate with the individual carrier plate.

Place all the four base plates in position along with their leveling screws andfoundation bolts.

Provisionally align and level all the four base plates.

Assemble protection sheet in the foundation bolt holes.


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ALIGNMENT OF PEDESTALS AND LP BASE PLATES

Provisionally align and level all the four pedestals including LP base plates withreference to the earlier marked longitudinal and transverse axis. Theelevation reference is to be taken from the already positioned plate forthis purpose.

Align and level LP rear pedestal and set the elevation as per machine center line.

Use piano wire arrangement with micrometer for centering of pedestal bore anduse water level jar for setting of elevation. Use measuring tape tomaintain pitching of the bearing from one pedestal to another. Pedestalsare to be set in level condition on both longitudinal and transversedirection. Align and level HP front, HP rear and LP front pedestals.Elevation of the pedestals are to be set as per catenary of the machineconsidering the half bore error of the pedestal if any.

Align and level, LP base plates. Elevation of LP base plate is to be kept higherthan the rear pair of LP base plate in line with catenary of rotor.

After alignment of LP rear pedestal weld the locating rings as mentioned in thedrawing.

During welding of locating ring, ensure that there is no movement in thepedestal in any of the direction.


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GROUTING OF PEDESTALS AND LP BASE PLATES

Fill 3 to 8 mm washed Pea-gravel in all the anchor bolts sleeves. These gravelare necessary to give damping effect to the anchor bolts during operationof the machine.

Seal anchor bolts holes after filling of gravel to avoid any entry of grout metal.Medical tape may be used for sealing of these anchor bolt holes.

Clean foundation with compressed air.

Make shuttering of all the pedestal and LP base plates. Use thick polythenesheet inside the shuttering to give better finish and avoid moistureabsorption by shuttering.

Shuttering should be made with maximum care to avoid any leakage of groutconcrete. All sides of the shuttering are to be sealed either with somesealing compound or with thick mixture of grout material to avoid leakage

of grout material.

Foundation are to be kept wet for about 6 hrs. before grouting.

Non shrinkage cement duly approved by BHEL is to be used for grouting of thepedestals and base plate.

Use fresh stock of the grouting material only and check the strength of thematerial before use.

During grouting, the mixture has to be poured from one end only and it has toflow to opposite end to avoid any blockage of air pocket.

Water curing is to be carried out for about 10 days duration.

All anchor bolts are to be stretched minimum after 21 days of grouting.

HP, IP & LP module placement work can be taken up after 24 hours of groutingof the pedestal and base plates.

For individual pedestal and base plate, grout mixture should be poured in one lotonly.

PLACEMENT OF HP MODULE IN POSITION

Ensure matching of all the four palms of the module where it is resting on thepedestals.

Ensure matching and parallelity of front and rear key block of the HP casing.

Assemble all four jacking screw of HPC and ensure their free movement.

Clean journals and coupling of the HP rotor.

Record journal dia, coupling hole sizes and spigot dia of HP rotor.


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Lift module in level condition and place it in position by keeping it 3 to 5 mmtoward front pedestal side.

During placement of module use temporary packers similar to permanent andadditionally support it by four jacking screws.

Ensure load on all four packers with the help of some additional shims ifrequired.

Install temporary radial and axial keys of the casing.

Prepare HP rotor for alignment (Ref. section 20 before placing the IP module.

PLACEMENT OF IP MODULE IN POSITION

Ensure matching of all the four palms of the module where it is resting on thepedestals.

Ensure matching and parallelity of front and rear key block of IP casing.

Assemble all four jacking screws of IP casing and ensure their freemovement. If these jacking screw holes are provided with the boltsfrom factory then same are to be removed before placement of module.

Clean IP rotor on both sides including coupling and journal.

Record spigot /recess, journal dia, and coupling hole sizes.

Lift the module in level condition and place the module in position by movingabout 7 to 8 mm towards generator end. Use temporary packers forplacement of module in position and additionally support the module withjacking screws.

Ensure load on all four packers with the help of some additional shims ifrequired.

Provisionally align the casing on front and rear pedestal bore. Install temporaryradial and axial keys of the casing with some shims.

Prepare IP rotor for alignment (Ref. section 20).

NOTE: In case IP module is sent to site in disassembled condition, referInstruction T1-08-0606G.

ASSEMBLY OF LP MODULE

This assembly can be divided in following sub assemblies:


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Assembly of girder and end walls.

Assembly of LP inner inner and LP inner outer casing lower half.

Assembly / welding of LP outer casing.

Before starting assembly of LP casing in position, following works arealso to be completed :

- Positioning and welding of LP casing centering pin of front and rearside.

- Positioning of key block of LP casing axial keys.

- Positioning of all internal of condenser.

POSITIONING AND WELDING OF LP CASING CENTERINGPIN

Two nos. centering pins are to be located below LP front and LP rear pedestal.Necessary pipe along with two sq. end plates are already provided in thefoundation to take the radial load of the LP casing:

Plumb the center line from LP front and LP rear pedestal bore on both sideover the square plate of the foundation.

Establish accurate position of the pin and put a punch mark at a required height

and mark a circle and a controlling circle over all the four sq. Plates.


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Dia of the circle must be equal to pin dia. A template equivalent to pin dia hasto be made for this purpose with about 20 mm thick plate and a weldedpipe for using as an handle. The template dia must be very accurate andsame may be made on machine.

Make precise hole with gas cutting/grinding to match template on all four

embedded plate. Ensure that the template is fitted with minimumclearance and hole center are perfect as per marking.

Drill hole of about 10 mm dia on one of square plate of LP front and on oneplate of LP rear for air venting to avoid cracks during welding.

Insert both the pins and carry out the welding as per laid down procedure.Before welding set correct axial position of the pins.

Insert key block on both the pins and weld their locking ring also. Ensureproper clearances in key block before welding of its locking ring.

Preheating of 200 degree Celsius or more to be achieved before any welding.Dye penetrate test on root run and after final welding is to be carried out.


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ASSEMBLY OF GIRDER AND END WALL

Colour match side matching flange of girder with the surface plate.

Colour match seating flange of girder where it rests over the LP base plate.

Match and ensure parallality of axial key ways of girder.

Colour match side flanges of end wall.

Match and ensure parallality of key block of end wall.

Place left and right girder with carrier plate, spacer and lubrite packer on LPbase plate.

Provisionally align and level the girders. Set height of the girder equivalent tomachine center line maintaining catenary of the machine with the help ofwater level jar arrangement.

Assemble locking plate of the front and rear end wall to facilitate its assemblywith the girders.

Assemble front and rear end wall with the girders and ensure perfect partingplane level during tightening.

Align, level LP outer casing and ensure contact of packers by colourmatching/machining of spacer height.

Install LP casing radial and axial keys.

Assemble inner outer casing axial key blocks on left and right side of girder

and dowel them.

Lock with tack welding all the vertical joint bolts.

Put a seal weld run between girder and end wall joint all around except on topface.

Weld girder and end wall parting plane joint with argon welding. Beforewelding make a V groove with the help of a chisel and allow the projectionof material on surface. Do not make the groove by grinding.

Do colour matching with a surface plate on all four corner where argon welding

have been carried out.

ASSEMBLY OF LP INNER INNER AND LP INNER OUTERCASING LOWER HALF

The LP inner inner casing lower half is received from factory in assembledcondition with LP inner outer casing lower half.


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Clean the casing and check all the threaded holes.

Do colour matching on all four corners of the casing where it rest over thegirder.

Colour match all eight carrier plates of inner casing on both side.

Assemble all carrier plates on girder and do the colour matching withindividual carrier plate.

Prepare Gusset plate of front and rear side with temporary radial keys for fittingin LP inner casing.

Level and lift LP inner outer casing and assemble/weld both the gusset plateswith the help of some temporary support.

Lower the casing in position over the carrier plates fitted with spacer and lubrite

packer.

Provisionally align the casing radially and axially.

Support the gusset plate with the help of screw jack (about 10-15 tons) on frontand rear side by taking support from condenser stiffeners. Screw jack is tobe unscrewed after box-up.


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Colour match and remove all high spots of the matching flange of the LPouter casing.

Ensure good contact between parted diffuser of LP front and LP rear cover.

Colour match and remove all the high spots of the parted diffuser/vertical face

to ensure good contact with the compensator at a later stage.

Colour match and remove all burrs and high spots from parting plane of LP outercasing.

Side flange of LP front and rear cover are to be ensured in right angle toachieve good contact with their matching flanges.

Place LP front LP rear cover along with parted diffuser and ensure feeler tightjoint after tightening the parting plane bolts. The joint must be feelertight just after normal tightening of bolts. Do not over tighten partingplane bolts.

Ensure matching of parted diffuser face on both side of LP casing. If necessarycolour matching may be carried out to achieve a feeler tight joint.

Drill/ream all the parting plane holes as per drawings and install all dowel pins.

After fixing of LP front and rear cover measure the dimension forpositioning of both the center flanges. The dimension are to be recordedin such a way that there is no clearance after fitting of center flanges inposition on both side with the LP front and rear cover. The centerflanges are supplied in extra length on both sides from the factory andfinal length are to be maintained at site only.

Drill/ream dowel pin holes in center flanges and install all dowel pins in position.Ensure drilling and reaming of all dowel pin holes to equal depth.

Fit both the center pieces of the cover in position.

Achieve the fitting clearances for welding as per laid down procedure.

Weld/lock LP upper half flange with respect to lower half casing with the helpof metal cleats to minimise the distortion during welding of LP cover.The cleats may be welded at an interval of about one meter distance.

Carry out the welding as per the following welding procedure.

WELDING PROCEDURE

Tack weld the crowned seam joint. permanently welding approx. 100 mm at thegenerator end of the joint.

Opposite tack welded radial joint 2, permanently weld approx. 100 mm of thecrowned seam joint, pos. 1, staggering the two weld ends to ensure aperfect transition when the crowned seam joint is finish welded.


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Tack weld the crowned seam joint at regular intervals with a tack of 5T and pitchof 25T.

When welding radial joint 2, shell plates 1 & 2, tacked together, rest on but arenot tacked to the retaining strip in the region of joint 1, so that anyshrinkage occurring during welding of seam 2 is not obstructed.

The tacking & welding sequence applies for all shells courses.

Weld radial seam at TE according to welding sequence plan.

Align, adjust and tack weld radial seam at GE.

Weld radial seam at GE according to welding sequence plan.

Weld crowned seam joint.

Align shell courses on joint strips and tack weld,

Weld on joint strips from center & ends of shell plate.

Insert pins in top half casing, release top half casing and lift to insert and tackfiller piece between joint strips.

Unbolt top half casing and lift in order to weld and finish - machine filler pieces inthe region of the joint surface.

Check welds according to specifications.

ALIGNMENT AND COUPLING OF LP-IP & HP ROTORLP rotor is to be aligned on pedestal seal bore and LP inner outer casing is to becentralised in such a way that enough clearances are available to LP rotor,during alignment. Now this alignment activity of all the three rotor can bedivided as below :


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Preparation of HP rotor for alignment.

Preparation of IP rotor for alignment.

Preparation of LP rotor for alignment.

Alignment of LP-IP & HP rotors.

Reaming, honing of the coupling holes.

Balancing of coupling bolts weight.

PREPARATION OF HP ROTOR FOR ALIGNMENT

Align HP rotor with reference to front and rear pedestal seal bore reading. Ifrequired move complete HP module along with the rotor.

Fix temporary radial and axial key of the casing on both front and rear side ofthe casing. Remove HP front upper half transportation device.

Lift module by 0.20 mm on front side by putting additional shims in frontpackers.

Insert HP front bearing in position.

Reduce 0.20 mm shims gradually and ensure about 0.10 mm load on the rotor. Ifrequired further lower the front side of the module to achieve the loadingon bearing by about 0.10 mm.


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Remove HP front lower half transport device gradually and ensure nomovement between HP casing and rotor. If necessary adjust shims ofHP casing front packers.

During loading of bearing always ensure that the rotor is not fouling inside the

casing with the shaft seals. This may be ensured by checking with feelergauge also.

Check axial position of HP rotor in front side on left; right and top positionfrom the rotor reference point to the HPC as given in the shop protocol.

Insert and load the bearing in HP rear end in similar way as carried out incase of HP front end and record axial position of rotor as per shopprotocol.

Lock axially HP rotor with some fixture along with the arrangement ofjacking screw for movement of rotor. This fixture may be mounted on rear

pedestal. Before locking of rotor ensure axial position of the shaft.

Center HP shaft with reference to HP casing front and rear spigot. If necessary,move the casing readily to achieve the centering. A fixture can befabricated at site for mounting the dial gauge on both the end of the rotorto check the centering of the shaft.

Use thick oil during rotation of shaft on the bearing.

Protect bearing from any of the dust particles. It is recommended to placeupper half of bearing in position to avoid dust and any other damage tothe shaft journal.

Realign the rotor shaft with respect to pedestal seal bore and if necessaryadjust the shims below spherical support of the bearing.

Care should be taken during alignment that radial and axial clearancesbetween rotor and casings does not get bridged.

Check HP rotor radial run out on journal and coupling.

Check axial run out on thrust collar and both the coupling faces of HP rotor.

Check axial float of the rotor. Compare values with shop protocol values. (Ref. T1-08-0802G). Deviations to be reported to Manufacturing Unit.

PREPARATION OF IP ROTOR FOR ALIGNMENT

The IP module is also to be prepared in line with the HP module. Howeveras IP rotor is provided with one side bearing and opposite side is coupledwith the HP rotor without a bearing, extra care is necessary duringalignment of rotor in IP casing. The additional point which are to be taken careare explained below :


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may be used. During balancing of coupling bolts following points are to be takencare.

Final balancing of the coupling bolts are to be done along with the couplingnut of individual bolt.

If all the coupling bolt hole sizes are same before/after reaming and honingthen all the bolts can be kept of equal weight.

If necessary adjust the weight of the bolts by machining the metal from the bolthead.

When the holes of the coupling are of different sizes then it must be seen thatwhether excess enlargement have been done at site or works. In suchcases if excess cutting have been done at site in a particular hole thencoupling bolt with excess weight are to be used. The amount of excessweight must be equivalent to the excess enlargement of hole at site. If aparticular hole of excess dia. is noticed from factory then it is assured that

the particular rotor is balanced with excess dia hole and there is noneed of providing excess weight bolt at site.

COLOUR MATCHING OF THRUST BEARING

After completion of reaming/honing and preliminary tightening of the couplingbolts, the colour matching of the thrust bearing pad have to be carried out withrespect to the thrust collar of the HP Rotor. During colour matching a goodcontact on all the pads of front and rear side are to be ensured with respect torotor collar by moving the rotor in +/- direction during its hand rotation. Followingpoints are to be taken care during colour matching.


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Thrust bearing must be axially locked with the help of axial keys during thecolour matching of the pads. Axial keys to be fitted while finalising thealignment of thrust bearing with rotor collar without pads.

Few drops of oil is to be put on journal portion of the thrust bearing duringrotation of rotor to ensure that the oil is not entering in pad portion of the

bearing.

Colour is to be applied on the thrust collar of the rotor.

If necessary move the spherical support of the bearing pedestal to ensure theequal thickness of the pads before fittment of axial keys of the bearing.

During moving of the spherical support in front or rear direction ensure thatthere is no left - right movement to the support otherwise that maycause misalignment of the bearing.

After colour matching of the thrust pad the axial zero position of the rotor is

achieved and this can be taken for all other future reference for setting ofaxial position of HP, IP & LP casing.

HP, IP and LP lower casing are to be set axially after fixing the axial positionof the rotor and their final axial keys can be installed at this stage.


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ALIGNMENT OF HP, IP & LP CASING

After completion of colour matching of the thrust bearing pads the casingalignment work can be taken up. The following points are to be taken carewhile aligning HP, IP and LP casing.

The roll check have to be carried out in HP, IP and LP casing to ensure thecorrect radial clearances of the casing.

TG deck springs are to be kept in floating condition while recording the rollcheck of LP casing. However the roll check of HP/IP casing may be carriedout before floating of TG deck for fitting of their radial keys but up anddown roll check of HP/IP casings are to be done with TG deck in floatingcondition as per the procedure TS/ST/ 01/0008/00/96.

Ensure that there is no obstruction in the movement of LP inner casing due towelding of any of extraction piping. The one of the joint of extraction

piping may be left free till completion of roll check of the casing.

The welding of steam inlet pipes between LP inner casing and LP girders are tobe taken up after completion of roll check of the casing.

HP, IP and LP casing are to be fitted with final packers and axial key immediatelyafter the roll check. During fitting of casing axial keys and palm packersensure proper contact on lubrite coating of the keys/packers to avoid anydamage of these coating during operation of the machine,

After completion of fitting of final keys and packers only the casing are to becleared for further works of welding of various pipe lines.

The gland steam, balancing leak of lines, steam inlet and exhaust pipes are tobe welded with HP casing after fitting of final axial keys and packers of thecasing.

Center HP rotor w.r.t. casing front and rear spigots. Compare the readings withshop protocol and record the readings.

Offset center line of the HP, IP & LP casing w.r.t. respective rotor center line asper recommended logsheet.


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Roll check of LP inner casing including the fitting of key, packers etc. must befinished.

All the works must be finished inside the LP casing before boxing up of LPcasing including LP extraction pipe line works.

Ensure matching of all parting plane holes and feeler tightness of the jointbefore boxing up of the casing.

Ensure feeler tightness of bursting diaphragm flange joint before boxing up ofthe casing.

Ensure proper assembly of parting plane rubber cord.

FINAL HORN DROP CHECK

After completing the welding of HP inlet, HP exhaust, IP inlet, IP exhaust

and other piping of HP/IP casing the final horn drop readings are recordedas per the laid down procedure mentioned in the manual for horn dropcheck. However the IP casing horn drop is also to be recorded with IPinlet upper half pipe welded with casing alone.


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This mixture is then taken into through heaped mesh. The hopper must be big enough

to make the full quantity of grout.

Than pour the grout with a hose through the filling hopper until the desired height is

achieved on the opposite side. (Flow may be accelerated by moving the grout in the

filling nozzles underneath the plates with chains or material strips.) This should be done

only if it is permitted by the grout supplier.

CAUTIONS

1. Do not use concrete vibrator.

2. Pour grout from one side only so that no air bubbles remains entrapped in thegrouting compound.

3. Due to short workability times, never mix more grouting compound at one time than

is required for one plate or volume to be grouted.

4. Pour in one continuous operation, without interruption.

5. Do not install any woven steel fabric reinforcing mats beneath the foundation plates.

6. It is desirable that in hot weather the grouting is done in the evening so that ambient

temperature is low during the initial setting time.

7. Water should be clean and free from dissolved chlorides, as these weaken the grout.

8. In case during the grouting operations heavy leakage is observed from the shuttering

that cannot be plugged during the grouting operation, and the level of grout has

fallen below the base plate level, it is desirable to wash out the complete grout. The

operation should be repeated after the shuttering has been rectified.

NOTE:- After at-least 72 hours setting time, work may be commenced on pre-

tensioning of the foundation both.

After the grouting compound has set (approximately. 24 hours after grouting), remove

all shuttering and smooth off the excess grout. The grouting compound is subjected to


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ASSEMBLY PROCEDURE OF IP MODULEDue to oversize dimension of the IP module (M30 - 63) and its limitation intransportation from Hardwar to site, the same will be dispatched to site in dismantledcondition in various packages after completing the shop assembly at Hardwar. Firstthe complete assembly of IP module will be done at works except the heat tightening ofparting plane bolts of IP inner and IP outer casing. Afterward complete casing will bedismantled and dispatched to site.

The above machines are equipped with the spring loaded foundation deck. As a

general requirement initially all the turbine and generator rotors will be aligned/coupled

without floating the TG deck. The coupling will be opened and again re-aligned after

floating of the TG deck which is generally done after erecting all the components of

Turbine -Generator including their piping etc.

ASSEMBLY PROCEDURE AT SITE :Place IP outer casing lower half in position after its cleaning over the pedestals by

supporting it on the Jacking screws at four corners of casing. Additionallysupport the casing on temporary packers with the pedestals also.

Align IP outer casing radially with the help of piano wire keeping the HP rear and IPfront pedestals seal as reference. Install temporary radial keys of the IP outercasing with the pedestal.

Clean and install IP inner casing lower half along with its radial keys (Drg. No. 0-106-01-27500 item No. 25) of front and rear end. During placement


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of inner casing support it on its four nos. Jacking screws. (Drg no. 0-106-01-27500# 18). After placement of inner casing install its axial keys (drg N. 0-106-01-27500 # 20). Before placement of inner casing install its thermocouple,parting plane studs (drg N. 0-106-01-27500 # 33 & 34 ). Seal ring of inlet insert& extraction line (drg N. 0-106-01-27500 # 3,4,9,10,13,14 ).

Place IP inner casing upper half in position and tighten alternate parting plane bolts.During this process the heat tightening the bolts are not necessary as this isrequired for ensuring the feeler tight parting plane joints of the IP inner casing.The IP inner casing packers are also to be installed during tightening of the P/Pbolts and load of the inner casing is to be transferred on these casing packers(drg N0-106-01-27500 # 17) fter taking the load on the packers release thejacking screws of the IP casing.

Loosen IP inner casing parting plane bolts and remove IP inner casing upper half.Before loosening the IP inner casing parting plane bolts support inner casingagain on its four jacking screws and ensure that the parting plane level of lower

half inner casing is not disturbed and remain same as it was kept after tighteningof parting plane bolts with load on its four packers.

Place IP rotor in position after its cleaning. The front end of the rotor is to be placedover segment (drg N. 0-106-01-27500 # 21) and rear end of the rotor on itsbearing. During placement of IP rotor ensure that the rotor is free on its seal finsof IP inner casing and necessary the IP outer casing may be lowered on its rearend.

Provisionally align and couple HP/IP/LP/ Generator rotors and complete reaming/honing of the coupling including swing check etc. Before rotation of IP rotorremove segment (drg N. 0-106-01-27500 # 21).

Set axial position of the IP rotor as per the zero position of the thrust bearing and setaxial position of the IP outer casing as per Hardwar protocol on front and rearend of the IP outer casing.

Align radially IP outer casing with reference to the IP rotor on front and rear glands.Recheck/correct axial position of the IP casing.

Assemble IP inner casing upper half end tighten the alternate parting plane bolts toensure feeler tight joint.

Do roll check of IP inner casing by moving the IP outer casing in left/right direction andIP inner casing itself in up/down direction with the help of inner casing jacking

screws by removing the inner casing packers. Ensure / compare roll checkvalues with shop records.

Check IP rotor axial float in IP inner casing and compare with shop protocol.

Loosen IP inner casing bolts and remove IP inner casing upper half.

Decouple and lift IP rotor for assembly of rear end shaft seals of IP casing. The frontend of the seals may also be assembled now of afterward with the IP rotor inposition.


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Place IP rotor in position and provisionally couple it with HP rotor on temporary bolts.The IP rotor may not be coupled at its rear end with the LP rotor at this stage.

Assemble and heat tighten IP inner casing upper half as per required elongation ofparting plane bolts. Install seal rings of inlet insert and extraction pipe on IPinnercasing upper half (drg N. 0-106-01-27500 # 1,2,7,8,11,12). The taper pins

of IP inner casing parting planes are to be removed before placement of IP outercasing upper half after the heat tightening of IP inner casing bolts.

Assemble IP outer casing upper half and tighten the parting plane bolts to ensure feelertight joints. The heat tightening of the bolts are not to be done now. Beforeplacement of IP outer casing upper half assemble casing shaft seals of front &rear end also.

Do roll check & float of completely assemble IP turbine and compare it with factoryprotocol.

Heat tighten IP outer casing parting plane bolts to required values, and carry out final

roll check and float of completely assembled turbine.

NOTE : These are general instructions for the assembly of IP

module M 30 - 63 at site. However, depending on the site

conditions the same may be suitably reviewed, if necessary.


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SEALING & ANTISIEZING COMPOUNDS

SNO LOCATION FEATURES RECOMMENDEDCOMPOUND

01 JOINT PLANE OF HPT IPT& VALVE CASINGS,GLAND BOXES &STRAINER HOUSINGS,BREECH NUT MATINGFACE.

METAL TO METALJOINT IN HIGHTEMPERATUREZONE

BIRKOSIT STAG B

MAGNESITECOMPOUND OFBHEL BHOPAL

JOINT PLANE OF LPOUTER CASING(WITHOUT RUBBERSEALING CHORD).

METAL TO METALJOINT IN LOWTEMPERATUREZONE

HOLDITE

LOCTITE 574

03 JOINT PLANE OF

BEARING PEDESTALS,MOP CASING, VALVESERVOMOTOR.

METAL TO METAL

JOINT IN OILENVIRONMENT

HYLOMER

GOLDENHERMETITE

VICTORSHELLAC

04 THREADED FASTNERSINCLUDING, BREECHNUT THREADS, KEYS,PACKERS, DOWEL PINSU & I - SEAL RINGS INHIGH TEMPERATURE

ZONE.

HIGHTEMPERATURE

( < 350c)ANTISIEZING

MOLYKOTE P37

OKS 255

05 THREADED FASTNERS,KEYS, PACKERS, DOWELPINS IN LOW TEMP.ZONE, COUPLING BOLTSSEAL SEGMENTS, HP/IPCASING PALM PACKERS,HP FRONT & REARBEARING PEDESTALPACKERS (OTHER THANSELF LUBRICATED

LUBRITE PACKERS).

LOWTEMPERATURE

( < 350c)ANTISIEZING

MOLYKOTE D 21

OKS 511

MGS 400

02

NOTE: NO COMPOUND IS TO BE APPLIED ON SELF LUBRICATED LUBRITEPACKERS.


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ASSEMBLY OF BEARING AT SITE

GENERAL DESCRIPTION

The KWU design machine are supplied with four bearings out of which three are thejournal bearing and one is combined thrust and journal bearing on H.P. rear end of the

shaft. All the turbine bearing are self aligning type and they adjust themselves asper the catenary of the machine.The function of a journal bearing is to support the turbine shaft , but the thrustbearing support the shaft as well as work as a fix point for the turbine shaft. The contactarrangements between bearing and bearing supports are of two types i.e. sphere tosphere in HP front and HP rear bearing and torus to cylindrical in other bearings.The bearings are supplied to site after ensuring their contact at works. During erectionall the bearing are supplied to site in aligned and assemble condition in their individualpedestal from the works. After alignment of the bearing in their pedestal the seat ofthe bearing are doweled before dispatch to site.In case of Thrust and Journal bearing the seat of the bearing neither doweled from

the works nor it is recommended to be doweled at site. The bearings needpreparation before placement of module in position at site. This can be done evenbefore the placement of pedestal in position for grouting.

ASSEMBLY PROCEDURE

1. After opening the pedestal remove and clean the bearing including its

spherical/ cylindrical seat.

2. Remove oil guard ring and its duct and keep them in proper place

for their storage at site.

3. Handle bearing carefully to avoid any damage to the babbit and

its torus/spherical piece. During storage at site avoid direct loading of

bearing on its torus. A thick rubber seat may be used during

handling of bearing at site on its torus.

4. Ensure 0.03 feeler tightness on bearing parting plane. In case of

any variation the matter may be referred to designers.

5. Measure bore dia of the bearing and journal dia at site and ensure

the oil clearances. If any discrepancy is observed , designer may be

referred.

6. Ensure torus/spherical contact with their seats at site. While checking

the contact the seat may be bolted with their pedestal. In case

variation contact from their specified diagrams are noticed then

following may be carried out at site:-

a) In case of torus to cylindrical seats the line contact are

recommended by designers. If these lines are not straight


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and are in angle then the bearing may be rejected straight way

and sent to works for rectification. These line contact may be in

a width of about 20 mm throughout on its seat leaving with

area on both sides. The contact may be wide in Center and then

gradually reducing on sides. In case there is no contact is

achieved in the center and only sides are having contact thena feeler gap may be recorded in bottom. In case if the bottom

is tight to a feeler of 0.03 mm the bearing may be accepted

at site without doing any rectification.

b) In a reverse case the contact are achieved in center only

though the 0.03 feeler is not going in the side. The bearing

may be still accepted at site. In case if the feeler is going in the

bottom or in sides by 0.03 mm. the bearing are not accepted at

site and can be sent back for the rectification to the works.

Similarly if the contact are intermittent on its seat but in a

straight line and no feeler is going the bearing may be accepted.

In case of very wide contact also the bearing may be sent back

for the rectification. While checking these contact very light

color may be put on torus of the bearing. Before sending back

the bearing to the works the matter may be referred to

designers and their concurrence is to be obtained. No

scrapping/lapping is recommended in these bearing for

improvement of the contact.

c) In case of spherical to spherical bearing the contacts are called

in the center like a moon shape. In these bearings even full

contact may be accepted. But in case if there are contact on

sides and a feeler gap is noticed on center then the bearing

may not be accepted.

In such cases if the gap is upto 0.03 mm then thematching/lapping may be carried out at site. But in case of highergap the matter may be referred to designers. In case of reversecase if the feeler gap of 0.03 is noticed on both sides of thebearing the bearing may not accepted at site and matter may bereferred to designers.


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7. Before checking the contact between torus and its seat ensure that the

seat is feeler tight to 0.03 mm without tightening of any bolts with the

pedestal. If necessary this may be corrected with consultation of

designers. Similarly ensure contact between torus\ spherical piece

with bearing and in case of variation the matter be referred to

designers and no correction is to be carried out at site without theapproval of manufacturing unit.

8. Before checking the contact between torus/spherical piece with

bearing and in case of variation the matter may be referred to

designers and no correction is to be carried out at site without their

recommendations.

9. The sizes of all the shims may be punched in bearing body and

spherical/torus piece of the bearing. The number of shims are to be

limited to 3-4 numbers only even after complete alignment of

machine. A protocol for number of shims may be prepared.

10. Torus/spherical should not have any radial movement over its

bearing. This can be seen after opening the torus from the bearing.

11. Check jacking oil lines of the bearing and clean them thoroughly.

Ensure jacking oil lines fittings also for their male female threads

etc otherwise this may create the oil leakage through these lines

during operation of the machine. The jacking oil pocket in the

bearing may be checked if necessary they may be corrected at site as

per the drawings.

12. When ever JOP is not available, use always thick oil during rotation

of shaft over bearing.The type of oil may be used as servo cylinder

1000 grade of IOC.

13. After installation of bearing in position the oil clearances may

be checked after few rotation of the shaft. But the final oil clearances

are to be checked after final coupling of the shaft. In case of

variation in side oil clearances no cutting of babbitt metal is

permitted at site. Any variation in clearances may be counter

checked by measuring journal / bearing bore dia. Bearing bore dia is

to be measured by assembling and tightening of top & bottom halvesof bearing.

14. In case of skew side oil clearances, the investigation may be carried

out, if necessary consult manufacturing unit.

15. Ensure good contact between journal and babbitt metal of the

bearing in the center. Any minor high spot may be removed from

the babbitt metal while checking with blue color. Ensure full

contact of shaft over the jacking oil pocket also.


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margin may be left for emergency work during overhauling of the

machine any adjustment during erection and normal overhauling

may be done by adjusting shims between spherical/cylindrical seat

and pedestal base only. For left and right adjustment the complete

pedestal of HP front and HP rear may be moved with the help of

their radial keys.The above discussed points were common for Journal bearingand combined thrust and journal bearing. Now some specificpoints are detailed here for the assembly of combined Thrustand Journal bearing:

Remove all the thrust pads before placement of bearing inposition and store them in a proper place.

Pressure proper fitting of babbitt metal liner in the bearing bodyincluding necessary pinch in the fitting of its liner.

During alignment of rotor along the bearing with respect to the

shaft by moving spherical seat of the bearing radially and axially.

No elongation of holes are to be carried out in spherical sat ofthe bearing for the purpose of its alignment.

Before deciding axial position of the bearing the axial position of the rotor is to bedetermined. If necessary the H.P. rear pedestal as a whole may be shifted axiallyto ensure correct position of the thrust bearing.

Align the thrust bearing in such a way that the thrust pad gapachieved are prallel and no difference are noticed in front and rearpad thicknesses.

Movement in the thrust pad should be ensured and a difference in

thickness of packers including shims should be with in + 0.10 mmmay be permitted on front and rear pad sizes in exceptional cases.

After ensuring the perfect alignment of the bearing the axial keysare fitted after assembly of upper half bearing. These axial keysare to be fitted in perfect parallel slots without any clearances.The keys are to be fitted in such a way that there is no movementto the bearing during fitting of these axial keys. Necessary dialgauges are to be installed on bearing during fitting of these keys.

After completion of axial key works of the bearing the thrust padsmay be fitted in the bearing with a clearance of about 0.10/0.15mm.

Before fitting of pads in the bearing ensure that there dimensionare made parallel to suit the front and rear slot size of the bearing(size between thrust collar and bearing body).

Ater fitting of pads in the bearing ensure their free movementover the bearing.

Install lower half bearing in position along with their pads and putvery small quantity of oil on journal then rotate the rotor and putblue color on the thrust collar of the rotor on both front and rearside.

Install upper half bearing along with all pads and fix their axial keys.


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Rotate the rotor and move + direction axially with the help ofwooden planks. Remove both halves of the bearing and see theblue contact on thrust pads. If necessary some cutting may becarried out on the pads to achieve the color contact. Thisexercise may be repeated few times to achieve the blue contact

Ensure a float of 0.30 + 0.10mm during color matching of thethrust pads. If necessary the minor adjustment of shims may becarried out in the bearing pads.

Before installation of thrust bearing along with thrust pads inposition the both halves may be bolted out side and their padsmay be checked for color contact over a surface plate also infront and rear both sides. This will reduce the time cycle whilecarrying out the color contact of the bearing with the rotor.

During overhauling of the unit the bearing contact are to berechecked and need correction. In case of torus to cylindricaltype of bearing if the contact are not satisfactory then thebearing and its seat may be remac

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