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STEAM TURBINE 500 MW ERECTION

INSTRUCTIONS FOR HANDLING & STORAGE

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 during handling and storage at site.

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 well lighted. The loads must not be lifted unless the crane operator can see clearly the signals given by the rigger. The positions where the slings are to be put, are marked on the packages and on the drawings. While lifting/handling these packages/equipment, the slings should only be put at the proper places. The slings of the proper sizes and lengths should only be used for handling the equipment/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 have proper loading of the sling. The turbine rotors and cylinder covers (in assembled condition are lifted by the use of special lifting devices supplied by BHEL. The use of these lifting devices facilitates correct slinging and maintain horizontal position of the components. These devices, after use, should be properly stored and conserved 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 by other hoisting mechanism should be entrusted to trained riggers only. If the rigger/operator is not sure of the weight of the item/package (load) to be handled, he must ask for the required information before handling the equipment.

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STEAM TURBINE 500 MW ERECTION

INSTRUCTIONS FOR HANDLING & STORAGE

The rigger and the crane operator should see that the hook and the ropes of the crane occupy vertical position, before hoisting the load. Dragging of the load by slanting ropes is not allowed. The center of gravity of the load should be aligned with the vertical axis of the crane hook. The eye bolts, 'D' shackles, turn buckles, and wire ropes of suitable sizes should only be used for handling of the equipment. Before using, they should be thoroughly inspected to their full threads, so as to avoid any chance of slipping then the load comes on them. Before giving a signal to lift the load, the rigger must check and ensure that there are no loose parts or tools on the load, which might fall during lifting. Then the load must be lifted 100 or 200 mm high for checking the uniformity of sling tensioning and reliability of lashing. If it is necessary to rearrange the sling lengths, the load must be lowered and then the slings rearranged. Before horizontal conveyance of the load the rigger must see that the load has been lifted to a height at least 0.5 M above the tallest object, on the path of the load. While the load is being conveyed, the rigger must accompany it and see that it is not moved above any person. Prior to lowering the load the rigger should examine the ground on which the load will be, lowered and make sure that 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 or lowering operation, he must give a signal for emergency grounding of the package or components. Smooth lifting and transportation of equipment must be ensured. Shocks and jerks should be avoided. All lifting devices, slings must be properly conserved after use and periodically inspected and tested. In the turbines having diaphragms, it is prohibited to handle diaphragms by putting slings in between the blades. For handling the welded diaphragms, special lifting devices is supplied by BHEL and the cast diaphragms are handled by putting the eye bolts, for which the provision of threads holes have been made in the diaphragms. While handling the bearings, it is prohibited to put the sling across the rabbit surface of the bearings. Threaded holes have been provided; in which the eye bolts have to be put for handling of the bearings. Bharat Heavy Electricals Limited Rev 00, 7-98 T1-08-0202G Page No. 2 of 11

STEAM TURBINE 500 MW ERECTION

INSTRUCTIONS FOR HANDLING & STORAGE

While handling the cylinders, it must be ensured that the slings or any other material does not get rubbed at their horizontal and vertical parting planes or at any other machined surface. The handling of the long components such as longitudinal girder, endwall etc. should be done with extra care. When they are placed on the floor, in addition to the end 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 no force is exerted on the free standing blades to avoid collapsing of clamping pieces under blade root.

MARKINGS ON PACKING CASES


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

INSPECTION
Before storing the equipment it should be opened for visual examination or the internal packing, protective coating and condition of the equipment. Any damage to packing and conservation should be immediately rectified. It is necessary to carryout first inspection within three weeks of arrival of the consignment. Thereafter, all the equipment should be inspected once in every three months to insure that the conservation is intact. During rainy season, the inspection should be done once in a month. At any time, if any original conservation is found damaged, it should be reconserved as per relevant conservation instructions No. ST 33004. While inspecting the packages containing rotors, special care should be taken to check the journals. In case of slightest sign of pitting on the journals and thrust collar, 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 of storage immediately after arrival at destination. This is very essential particularly during the rainy season. Bharat Heavy Electricals Limited Rev 00, 7-98 T1-08-0202G Page No. 3 of 11

STEAM TURBINE 500 MW ERECTION

INSTRUCTIONS FOR HANDLING & STORAGE

Store houses fall into the following categories

TYPE OF STORE HOUSE 'P'

CONDITIONS
TEMP. +50 C to 500 C upto 500 C RELATIVE HUMIDITY < 70 % ARRANGEMENT Totally enclosed, rain proof, ventilated and dry with cemented floor. Roofed area with walls (of brick / asbestos/ GI sheet ) around and cemented / pucca hard floor. Raised platform with shed of asbestos / GI sheet / water proof tarapaulin. Raised Platform.

'Q'

'R' 'S'

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INSTRUCTIONS FOR HANDLING & STORAGE

The platforms and store-houses should be built up in conformity with the fire prevention rules and standards. Complete storage area especially the R & S catagory must be adequately fenced & protected against theft & pilferage. These store houses and areas around them should have proper drainage facility for the 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 been stored. Store house should be provided with proper ventilation facilities. Level should be maintained for all the packages and equipment and should be uniformly supported to avoid distortion. The long packages should be supported at intermediate places also, so as to avoid sagging during storage. Store houses should preferably be equipped with proper lifting devices to ensure normal 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 using required number of wooden spacers 50 mm thick. In doing so, lighter packages would be laid upon heavier once to avoid any damage to lower packages. 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 after placement of the component on cemented/pucca hard floor.

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INSTRUCTIONS FOR HANDLING & STORAGE

STORAGE OF STEAM TURBINE COMPONENTS


SNO.

DESCRIPTION OF THE COMPONENT


FOUNDATION BOLT EMBEDDED PARTS (ADDITIONAL) COMPONENTS OF BASE PLATE ASSLY. BASE PLATE LP CASING LP OUTER CASIONG LONGITUDINAL GIRDER (LEFT & RIGHT) LP FRONT WALL (TS&GS) LP SHAFT SEALING (FRONT & REAR) AUXILIARIES OF TURBINE HP/IP BEARING PEDESTAL HP/IP BEARING PEDESTAL ASSEMBLY PARTS IP/LP PEDESTAL ASSEMBLY LP/GEN. PEDESTAL BEARING PEDESTAL PARTS FRONT BEARING PEDESTAL LIFTING BEAM LP CASING EXTRACTION A1 LP EXTRACTION A2 LP EXTRACTION A3 LP EXTRACTION PIPE SHEATHING INNER GUIDE PLATE DIFFUSER DIFFUSER (UPPER & LOWER HALVES) LP INNER-OUTER CASING (VH) LP INNER CASING ASSEMBLY (LH & VH) HEATING DEVICE LP CASING ASSEMBLY LP INNER CASING ASSEMBLY (FASTENER) INNER GUIDE PLATE DIFFUSER (GS)

TYPE OF STORAGE

1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

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INSTRUCTIONS FOR HANDLING & STORAGE

29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59.

LP ROTOR IP TURBINE IP TURBINE PARTS IP INLET PIPES HP TURBINE HP INLET ASSEMBLY HP EXHAUST ELBOW HPT RELATED PARTS FRAME FOR SUSPENSION (ESV) SUSPENSION OF VALVE (ESV) ESV & CV CASING WITH VALVE ESV SERVOMOTORS WITH LIMIT SWITCH HP CONTROL VALVE SERVOMOTORS SUSPENSION OF VALVE (IV) IV & CV CASING WITH VALVE IV SERVOMOTORS WITH LIMIT SWITCH IP CONTROL VALVE SERVOMOTORS FRAME FOR SUSPENSION (IV) IV SERVOMOTORS WITH LIMIT SWITCH STEAM BLOWING & HYD. TEST DEVICE TOOLS FOR GOVERNING SYSTEM SUSPENSION OF LPB VALVE WATER INJECTION VALVES CHEST LPB WITH STOP & CONTROL VALVE LPB STOP VALVE SERVOMOTOR LPB CONTROL VALVES SERVOMOTORS INJR. FOR SUCTION PIPE NB 350 INJR. FOR SUCTION PIPE NB 300 MAIN OIL TANK MAIN OIL TANK & NOZZLE ASSEMBLY OIL STRAINER

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INSTRUCTIONS FOR HANDLING & STORAGE

60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82.

LEVEL MONITOR INSTALLATION INSTRUMENTS LEAKAGE / DIRTY FLUID TANK VARIABLE ORIFICES & THROTTLE CONTROL FLUID TANK CONTROL FLUID TANK NOZZLE ARRANGEMENT EXPANSION TANK FILTER & PR. DAMPING DEVICES CROSS AROUND PIPE SUPPORT FOR CAP CHANGE OVER VALVE RATING & MONOGRAM PLATES OIL STRIPER HOUSING FOR HRH STEAM STRAINER HOUSING FOR MAIN STEAM STRAINER MS & HRH STR.HSG GASKET STEAM STRAINER MS STEAM STRAINER HRH COMPENSATOR TURBINE CONTROL LPB / SUPPLY RACK TEMPERATURE & PRESSURE CONNECTIONS PR. TRANSMITTERS BAR. PROBES THERMOCOUPLES TRANSMITTERS & JUNCTION BOXES

Q Q R Q R R R Q R R R Q R R R Q Q Q Q Q Q Q Q

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INSTRUCTIONS FOR HANDLING & STORAGE

STORAGE & PRESERVATION OF COMPONENTS OF TURBOGENERATOR, EXCITER AND SYSTEMS


SNO.

DESCRIPTION OF THE COMPONENT


EMBEDDED PARTS FOUNDATION PARTS WOUND STATOR WITH GAS COOLERS TURNION FOOT PLATES ROTOR ASSEMBLY OF PIPE CONTROL FOR GAS COOLERS END SHIELDS FAN SHIELD, GEN VVIEW HEADER ASSEMBLY TERMINAL BUSHING AND HEADER ASSEMBLY BEARING WITH BRUSH GEAR SEAL BODY TEMP. CONNECTION CASING FOR TURNIONS ERECTION MATERIALS ERECTION DEVICES SHAFT SEALS SEAL RINGS ADOPTING RING AUXILIARY BEARING CENTRIFUGAL FAN CARBON DIOXIDE VAPOURISER FILTER O.C.P. EXPANSION TANK OIL SEPARATOR PRE CHAMBER S.O.S.T. SEAL OIL UNIT HYDROGEN DISTRIBUTION

TYPE OF STORAGE

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

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INSTRUCTIONS FOR HANDLING & STORAGE

R 29. CARBON DIOXIDE DISTRIBUTION P 30. VALVES FOR AUXILIARY SYSTEMS Q 31. GAS UNITS Q 32. FLEXIBLE LEADS STORAGE & PRESERVATION OF COMPONENTS OF HEAT EXCHANGERS
SNO.

DESCRIPTION OF THE COMPONENT

TYPE OF STORAGE

PRODUCT : CONDENSER 1. BOTTOM PLATE 2. LOWER DOM WALL 3. SIDE WALL 4. WATER CHAMBER 5. UPPER DOM WALL 6. STIFFENING PIPES 7. STIFFENING RODS 8. TUBE SUPPORT PLATE 9. WATER BOX 10. AIR EXTRACTION PIPING 11. HOTWELL 12. SPRING ELEMENTS 13. LOOSE ITEMS 14. INSTRUMENTS 15. CONDENSER TUBES (STAINLESS STEEL) 16. CONDENSER TUBES (NON-FERROUS) 17. VACUUM PUMP 18. EJECTOR 19. AIR MEASURING DEVICE PRODUCT : HEATER 20. 21. 22. 23.
GLAND STEAM CONDENSER STAND PIPE INSTRUMENTS DRAIN COOLER R Q Q R

S S S Q S S S R R R S R Q Q R Q Q R Q

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INSTRUCTIONS FOR HANDLING & STORAGE

24. 25. 26. 27. 28. 29. 30.

L.P.HEATERS PRODUCT : COOLER OIL COOLER CONTROL FLUID COOLER STATOR WATER COOLER HYDROGEN COOLER EXCITER AIR COOLER INSTRUMENTS / LOOSE ITEM

R R R R Q Q Q

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INSTRUCTIONS FOR HANDLING & STORAGE

MAXIMUM PERMISSIBLE LOADING FOR WIRE ROPES IN KG.


NOMINAL DIA (d) OF ROPES mm
9 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120

SINGLE CORD
522 1170 2150 3850 6200 9000 12200 16000 20200 24900 30100 35800 42100 48800 56000 63700 71900 81000 89900 99700

DOUBLE CORD WITH INCLUDED ANGLE OF


0o 1044 2340 4300 7700 12400 18000 24400 32000 40400 49800 60200 71600 84200 97600 112000 127400 143800 162000 179800 199400 45o 965 2070 4000 2100 11500 16600 22600 29500 37300 46000 55700 66200 77700 90200 103500 117700 132900 149700 166100 184300 90o 738 1580 3060 5400 8800 12700 17300 22600 28500 35200 42600 50700 59500 69000 79200 90000 101700 114500 127100 141100 120o 522 1170 2150 3850 6200 9000 12200 16000 20200 24900 30100 35800 42100 48800 56000 63700 71900 81000 89900 99700

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