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FEED BACK ON EFFECTS

OF FOUNDATION ON
PERFORMANCE OF
MACHINES
N S TOMAR
DGM (T)
POWER SECTOR TECHNICAL SERVICES, NOIDA

FEED BACK ON :EFFECTS OF SPRING LOADED TG DECK


FOUNDATION ON PERFORMANCE OF
MACHINES

EFFECTS OF RIGID TYPE TG DECK


FOUNDATION ON PERFORMANCE OF
MACHINES

POWER SECTOR TECHNICAL SERVICES, NOIDA

BRIEF HISTORY : IN EARLY 80, BHEL SUPPLIED ALL TURBINE


GENERATOR

SETS

ON

RIGID

TYPE

OF

FOUNDATIONS.
MACHINE DESIGNER WERE:

CEA ENGLAND (120 MW) , UKAI, AMARKANTAK,


KORBA etc

LMW RUSSIAN (200/210, 100), WANAKBORI, UKAI,


BADARPUR, SINGROLI etc
SKODA (110 MW) , PANIPAT, KOTA, ENNORE.
SIEMENS (120 MW), SIKKA, NALCO. etc
POWER SECTOR TECHNICAL SERVICES, NOIDA

NON-BHEL SETS

RAICHUR- 4, JAPAN

NUCLEAR SETS , KOTA, etc .

THESE MACHINE ARE RUNNING SINCE


LONG WITHOUT MUCH PROBLEMS DUE
TO FOUNDATIONS.

THESE MACHINE HAVE

FACED MAJOR

EARTH QUAKE IN LATUR AND GUJRAT.


NO MAJOR PROBLEMS REPORTED.

POWER SECTOR TECHNICAL SERVICES, NOIDA

KWU SETS

IN LATE 80S, BHEL COLLABORATED WITH KWU.


INITIALLY TROMBAY -5, CHANDERPUR 5 & 6 AND
OTHERS MACHINE WERE SUPPLIED ON RIGID
TYPE OF FOUNDATIONS.

FIRST TIME TROMBAY -6, KWU INTRODUCED M/s


GERB ,A GERMAY CO AS SPRING SUPPLIER AND
SPRING LOADED TG DECK WAS SUPPLIED.
POWER SECTOR TECHNICAL SERVICES, NOIDA

FOLLOWING ADVANTAGES WERE CLAIMED BY


M/S GERB, GERMANY.

REDUCTION IN BASE MATE SIZE AND ITS


COST.

REDUCTION IN NUMBER OF COLUMNS.

EASY IN HANDLING OF FOUNDATION


SETTLEMENT PROBLEMS / EASE OF
ALIGNMENTS.

SUBSEQUENT TUNING OF THE


FOUNDATION.

EARTH
QUAKE
POWER
SECTOR PROTECTIONS.
TECHNICAL SERVICES, NOIDA

TENDER SPECIFICATIONS
CUSTOMERS LIKE NTPC AND OTHER BOARDS
STARTED PUTTING

SPRING LOADED TG DECK

IN TENDER SPECIFICATIONS.

MOST OF THE CIVIL FOUNDATIONS REMAINED


OUT OF BHEL SCOPE.

POWER SECTOR TECHNICAL SERVICES, NOIDA

PROBLEMS BEING FACED :

AFTER DECK CASTING.

DURING SEQUENTIAL ERECTION.

FLEXIBILITY OF ERECTION.

OPERATION.

OVER HAULING.
POWER SECTOR TECHNICAL SERVICES, NOIDA

AFTER DECK CASTING.

BEFORE TG DECK CASTING , SPRINGS ARE PRE


COMPRESSED TO 125-130% OF DESIGN LOAD.

SPRINGS ARE LOCKED WITH TIE-RODS, SO


THAT

DURING

ERECTION

THEIR

HEIGHTS

SHOULD NOT CHANGE.

DECK

HEIGHTS,

PARALLALISM,

HORIZONTALITY OF DECK TO THE

AND

GROUND

SHOULD BE REAMINED UNCHANGED.

AFTER DECK CASTING SPRINGS AT BOTH


ENDS OF DECK GET COMPRESSED AT ALL THE
SITE.
POWER SECTOR TECHNICAL SERVICES, NOIDA

AFTER DECK CASTING.

TIE RODS OF SPRINGS BECOMES LOOSE .

DECK LOAD IS ONLY 50% OF TOTAL LOAD.

HORIZONTALITY GETS DISTURBED.

POWER SECTOR TECHNICAL SERVICES, NOIDA

DURING SEQUENTIAL ERECTION

DURING SEQUENTIAL ERECTION OF TURBINE


GENRATOR , DECK HORIZONTALITY, SLOP etc
GOING ON CHANGING BY PUTTING LOAD ON
THE DECK.

FINALLISING KEYS, PACKERS, CATENARY ,


ALIGNMENTS etc BECOMES DIFFICULT TILL
FULL LOAD IS ACHIEVED ON DECK.

ERECTION CYCLE TIME INCREASES, WORK IS


REPEATED TILL THE END OF WORK.

POWER SECTOR TECHNICAL SERVICES, NOIDA

DURING SEQUENTIAL ERECTION

DURING CONDENSER NECK WELDING, WORK


ON DECK HAS TO BE STOPPED, OTHER WISE
CHANGING DECK SLOP CAN DISTURBE THE
NECK WELDING.

BEFORE NECK WELDING COMPLETE LOAD ON


CONDENSER SHOULD HAVE COME.

OTHERWISE IT CAN CHANGE LOAD SHARING


PATTERN BY CONDENSER AND DECK SPRINGS.

POWER SECTOR TECHNICAL SERVICES, NOIDA

FLEXIBILITY OF ERECTION.

IN CASE OF RIGID TYPE OF FOUNDATION,


FINALLISING OF PACKERS, KEYS , SLOP ,
CATENARY , ALIGNMENT etc ONCE MADE,
SHALL

NOT

DISTURBED

THROUGH

OUT

ERECTION CYLCLE.

ERECTION

ENGINEERS

ARE

HAVING

FLEXIBILITY OF ERECTION DEPENDING ON THE


AVAILABILITY

MATERIAL, MAN POWER, TIME

etc. THAT IS NOT POSSIBLE IN SPRING LOADED


TG DECK.
POWER SECTOR TECHNICAL SERVICES, NOIDA

OPERATION.

ALIGNMENT,
DISTURBED

CATENARY
WITHIN

FOUND
SHORT

HEAVILY
SPAN

OF

OPERATION. KHAPERKHED, SANTALDIH, NEW


PARLI,LEHRAMOHABAT , SIPAT etc

BHEL WAS FORCED TO ISSUE A TCHNICAL


CIRCUALR

TO

RE-CHECK

ALIGNMENT

CATEANRY WITHIN ONE YEAR OF OPERATIOPN.

THIS IS WASTAGE OF MONEY , TIME FOR


KEEPING MACHINE OUT OF GRID.

POWER SECTOR TECHNICAL SERVICES, NOIDA

OPERATION.

CHANGES IN ALIGNMENT, CATENARY DURING


OPERATION CAN CAUSE HIGH VIBRATIONS AND
BARRING GEAR JAMMING. RECENTLY SIPAT 4
AND 5 , CORRECTED.

BALLARY

1,

BARRING

GEAR

JAMMING

PROBLEM, ADVISED TO RECHECK CATENARY


AND ALIGNMENT.

INCASE OF TOTAL POWER FAILURE, ALL


RUNING CW PUMPS TRIP. DUE TO LOSS OF CW
WATER IN CONDENSER, DECK GET LIFTED ,
DIFORMS

DECK SLOP, CAN CAUSE BARRING

GEAR JAMMING
POWER SECTOR TECHNICAL SERVICES, NOIDA

OVER HAULING.

CYCLE TIME OF OVER HAULING INCREASES, AS


WORK

INCREASES

DUE

TO

HEAVY

MISALIGNMENT, CATENARY DISTURBANCE etc.

ADJUSMENT

IN

DECK

SPRINGS

NEEDS

ADJUSMENT IN CONDENSER SPRINGS ALSO.

SURATGARH,TALCHER, GENERATOR HAD TO


BE

SHIFTED TOWARDS LP TURBINE DUE TO

EXPANSION OF DECK.

IN RIGID TYPE OF FOUNDATION ,GENRATOR


SHIFTING WAS NOT OBSERVED.
POWER SECTOR TECHNICAL SERVICES, NOIDA

KOTA 6 COMPARISION OF b MEASUREMENT BEFORE AND AFTER CASTING DECK


Spring

Measurement before casting deck

Measurement after casting deck


182.2

Difference of readings

183.5

183.5

183.5

183.5

181

183.5

183.5

183.5

183.5

182.78

182.49

183.5

183.5

183.5

183.5

183

182.55

186

186

186

186

185.22

186.5

186.5

186.5

186.5

185.5

185.5

185.5

185.5

185

185

185

185

186

186

186

186

184.95

184.95

1.05

1.05

13

186

186

186

186

185.9

186.06

0.1

-0.06

14

184

184

184

184

183.77

183.6

0.23

0.4

15

186

186

186

186

180.7

180.85

5.53

5.15

16

185

185

185

185

177.66

187.78

8.24

7.34

22

183.5

183.5

183.5

183.5

183.12

183.14

0.38

0.36

23

184.4

184.4

184.4

184.4

183.82

24

185.5

185.5

185.5

185.5

184.92

184.86

0.58

0.64

26

185

185

185

185

18414

184.47

0.86

0.53

27

185.5

185.5

185.5

185.5

184.79

184.9

0.71

0.6

28

184.4

184.4

184.4

184.4

182.52

182.94

1098

1.56

29

185.5

185.5

185.5

185.5

185.04

185.15

046

0.35

31

185.5

185.5

185.5

185.5

183.69

183.95

1.81

1.55

33

186

186

186

186

185.65

186.08

0.35

-0.08

34

184.5

184.5

184.5

184.5

183.75

184.08

0.75

0.42

35

186

186

186

186

180.09

179.27

5.91

6.73

36

185

185

185

185

179.45

177.76

8.55

7.24

0.72

1.01

0.5

0.95

185.55

0.78

0.45

183.48

183.85

3.02

2.65

184.54

184.84

0.96

0.66

182.84

183.2

178.98

183.93

182.22

182.97

182

178.98

183.95

181.9

0.58

1.3

2.5

0.66

0.53

1.8

3.0

-2.78

6.02

0.47

0.45

2.28

2.6

8.95

KOTA 6 COMPARISION OF b MEASUREMENT BEFORE AND AFTER CASTING DECK


Spring

Measurement before casting deck

Measurement after casting deck


182.2

Difference of readings

183.5

183.5

183.5

183.5

181

183.5

183.5

183.5

183.5

182.78

182.49

183.5

183.5

183.5

183.5

183

182.55

186

186

186

186

185.22

186.5

186.5

186.5

186.5

185.5

185.5

185.5

185.5

185

185

185

185

186

186

186

186

184.95

184.95

1.05

1.05

13

186

186

186

186

185.9

186.06

0.1

-0.06

14

184

184

184

184

183.77

183.6

0.23

0.4

15

186

186

186

186

180.7

180.85

5.53

5.15

0.72

1.01

0.5

0.95

185.55

0.78

0.45

183.48

183.85

3.02

2.65

184.54

184.84

0.96

0.66

182.84

183.2

182.97

182

1.3

2.5

0.66

0.53

1.8

3.0

16

185

185

185

185

177.66

187.78

178.98

22

183.5

183.5

183.5

183.5

183.12

183.14

23

184.4

184.4

184.4

184.4

183.82

24

185.5

185.5

185.5

185.5

184.92

184.86

0.58

0.64

26

185

185

185

185

18414

184.47

0.86

0.53

27

185.5

185.5

185.5

185.5

184.79

184.9

0.71

0.6

28

184.4

184.4

184.4

184.4

182.52

182.94

1098

1.56

29

185.5

185.5

185.5

185.5

185.04

185.15

046

0.35

31

185.5

185.5

185.5

185.5

183.69

183.95

1.81

1.55

33

186

186

186

186

185.65

186.08

0.35

-0.08

34

184.5

184.5

184.5

184.5

183.75

184.08

0.75

0.42

35

186

186

186

186

180.09

179.27

5.91

6.73

36

185

185

185

185

179.45

177.76

8.55

7.24

183.93

182.22

178.98

183.95

181.9

8.24

7.34

0.38

0.36

0.58

-2.78

6.02

0.47

0.45

2.28

2.6

8.95

KOTA6 COMPARISION OF b MEASUREMENT BEFORE & AFTER PLACING GEN.


SPRIN
G

BEFORE

PLACING

GEN

AFTER PLACING GEN

DIFFERENCE

182.80

183.10

183.00

182.65

182.80

182.65

182.72

182.40

000

0.45

0.28

0.25

183.35

182.90

183.10

183.00

183.00

182.35

182.95

182.95

0.35

0.55

0.15

0.05

183.00

182.5

182.40

183.00

182.90

182.90

182.90

182.90

0.10

0.85

0.50

0.10

184.80

185.30

185.15

185.05

185.30

185.30

185.30

185.30

0.50

0.00

0.15

0.25

186.90

185.80

185.70

185.80

186.08

186.08

186.07

186.00

0.82

0.28

0.37

0.20

183.35

183.55

184.30

184.00

183.35

183.40

183.40

183.42

0.00

0.15

0.90

058

184.50

184.05

184.75

185.00

184.45

184.65

184.34

184.25

0.05

0.60

0.41

0.75

185.69

185.69

185.69

185.00

185.00

185.00

185.10

184.85

0.69

0.69

0.59

0.15

184.65

184.70

185.35

185.50

184.35

184.35

184.35

185.22

0.30

0.35

1..00

0.28

10

186.15

185.55

185.55

185.69

185.90

185.95

185.35

185.60

0.25

0.40

0.20

0.09

11

186.30

186.00

185.60

185.55

185.70

185.30

185.40

185.55

0.60

0.70

0.20

0.00

12

185.75

185.80

185.70

185.20

185.85

185.85

185.70

185.60

-0.10

-0.05

0.00

-0.40

13

185.50

185.85

185.15

185.20

184.50

184.50

184.50

184.85

1.00

1.35

0.65

035

14

183.25

182.70

183.50

184.40

182.40

182.23

182.20

183.30

0.85

0.47

1.30

1.10*

15

185./55

185.05

184.45

183.85

184.50

184.50

181.55

183.25

1.00

0.55

2.90

0.60*

16

182.45

183.15

181.90

182.40

182.40

182.80

184.50

181.85

0.05

0.35

-2.60

055*

KOTA6 COMPARISION OF b MEASUREMENT BEFORE & AFTER PLACING GEN.


SPRING

BEFORE

PLACING

GEN

AFTER PLACING GEN

21

183.02

182.10

182.10

182.10

22

181.75

182.37

181.05

180.65

182.00

23

180.00

183.05

183.85

183.90

24

184.83

184.74

184.7

25

186.10

186.35

26

184.13

27

DIFFERENCE

182.03

183.10

0.07

-1.00

182.30

182.00

182.10

-0.25

0.07

-0.95

-1.45

183.90

183.85

183.80

183.90

-3.90

-0.80

0.05

0.00

184.80

184.80

184.75

184.85

184.90

0.03

-0.01

0.15

-0.10

185.80

185.55

185.85

185.90

185.85

185.85

0.25

0.45

-0.05

0.30

184.50

184.45

184.40

184.15

184.50

184.20

184.20

-0.02

0.00

0.25

0.20

184.35

184.85

184.30

184.85

184.64

18474

184.30

184.64

-0.29

o.11

0.00

0.21

28

184.95

184.35

184.30

184.35

184.45

184.46

184.11

184.15

0.50

-0.11

0.19

0.20

29

184.95

185.10

185.25

185.15

184.79

184.90

184.04

184.95

0.16

0,20

1.21

0.20

30

184.70

184.90

185.10

184.90

184.45

184.70

184.45

814.75

0.25

0,20

065

0.15

31

184.60

184.50

185.00

184.80

184.90

184.64

184.60

184.90

-0.30

0.15

0.40

-0.10

32

186.60

185.90

185.90

186.60

185.00

185.00

184.95

185.00

01.60

0.90

0.95

1.60

33

185.20

185.60

185.40

185.35

185.00

185.00

185.20

185.00

0.20.

0.60

0.40

0.35

34

182.50

183.50

184.10

183.35

182.00

183.00

183.95

182/90

0.50

0.50

0.15

0.45

35

184.50

183.83

184.00

183.80

183.91

183.21

183.15

183.55

0.59

0.59

0.85

0,25

36

182.60

184.10

184.101

184.75

182.50

183.60

183.75

181.50

0,1

0.50

0,35

3.25

NEW PARLI-2 (Under Erection)

LOCATION

Design catenary value as per drawing

+2.94

+2.10

+1.64

0.00

Catenary before placing Generator

+2.86

+2.12

+1.66

0.00

Catenary after placing Generator

+4.05

+3.29

+2.6

0.00

PEDESTAL

KHAPERKHEDA-4
LOCATION

PEDESTAL

Design value as per drawing

+2.52

+2.05

+1.8

0.00

During Commg. Dt 23/12/2000

+2.65

+1.92

+1.30

0.00

During 1st O/H Jan 2003

+3.05

+1.80

+1.30

0.00

During 1st COH 18/07/2004

+2.50

+1.55

+0.60

0.00

During forced outage 25/12/2005

+2.60

+1.80

+1.45

0.00

During Brg inspection on Dt 20/09/2006

+3.57

+1.96

+1.40

0.00

SANTALDIH-5
LOCATION
PEDESTAL

0.00

-0.01

+2.75

+6.27

+1.55

0.00

+0.35

+0.49

0.00

+0.66

+4.53

+6.30

+1.83

+1.27

0.00

+0.55

+6.05

09.18

Design value as per drawing

+2.93

+2.10

+1.64

During releasing and adjustment


of Spring Units on 26.10.2007

+2.80

+2.00

Before re-adjustment on
21.09.2008

+0.77

After re-adjustment on 30.09.2008

+2.90

BHATINDA LM-3

LOCATION

Design value as per drawing

+2.41

+2.27

+1.58

0.00

Pedestal parting plane Before correction

+3.00

+2.35

+0.71

0.00

Pedestal parting plane After correction

+2.35

+2.25

+1.23

0.00

Correction in bearing parting plane for


alignment

0.00

-0.20

+0.10

0.00

PEDESTAL

NEW PARLI-1

LOCATION

PEDESTAL

Design value as per drawing

+2.94

+ 2.10

+ 1.64

0.00

Erection value

+3.12

+1.97

+1.45

0.00

Dismantling value

+1.28

+0.39

+0.16

0.00

Corrected final values

+3.70

+2.27

+1.10

0.00

TROMBAY-6
LOCATION
1

Design value as per drawing

+5.75

+4.28

+2.52

0.00

+15.74

Erection Values ( Jan 1990)

+6.35

+3.72

+1.3

0.00

+19.06

Before 1st Overhaul ( Nov 1994)

+3.88

+1.49

-1.81

0.00

+16.64

Before 2nd Overhaul (09/02/1997)

+4.00

+0.85

-1.4

0.00

+17.17

After overhaul (16/02/1997)

+7.27

+3.62

-0.61

0.00

+18.0

PEDESTAL

TROMBAY-6

CATENARY VALUES
CATENARY HEIGHT (MM)

25

20

15

Design Values
Erection Values
Before 1st Overhaul
Before 2nd Overhaul
After over haul

10

0
1

-5

PEDESTAL NO.