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ERECTION MANUAL

FOR
5X55 MW

HYDRO TURBINE
FOR
ALMATTI HYDRO POWER STATION
KARNATAKA POWER CORPORATION LIMITED

BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION

CONTENTS
S.NO -

DESCRIPTION

PAGE NO.

1.

STORAGE AND HANDLING INSTRUCTINS

3 - 11

2.

GENRAL GUIDELINES FOR ERECTION

12 - 24

3.

TECHNICAL DATA

4.

ERECTION OF EMBEDED PARTS

25- 28

5.

ERECTION OF FOUNDATION PARTS

29 -36

6.

TURBINE ASSEMBLY

37 - 63

7.

AUXILLARIES

64 - 67

8.

ANNEXURE -(LOGSHEET) `

68

STORAGE AND HANDLING INSTRUCTIONS
1. GENERAL
1.

The instructions given here are to serve as compendium for Storage
and handling of the Hydro Turbine components.
The technology of packing and also design of components are
constantly being improved and hence the instructions given here are
subject to modifications. Effort has beer, made to cover as many
aspects as can be foreseen at the moment. The aim of proper storing
and handling is to ensure trouble free erection and operation. It has
been pre-supposed that the operators and supervisors who will handle
these are conversant with general engineering practices and
sufficiently skilled in material handling.

2.

The following publications by British Standard Institute will be most
helpful.

1.2
1.2.1

i)

B.S. 113-1967 - Packing Code Sections 1 TO 6 and section 19.

ii)

B.S. Hand Book No.4 part 1 and 2 'Lifting Tackle'.

RECEIVING AND UNLOADING
The components are packed for their safe transportation -from the
manufacturers works to the site and this packing is unsuitable for long
time storage in open air after the packages have reached the erection
site.

1.2.2

Before unloading a packing case from the carrier the following
instructions painted on the packing case should be noted.

1.2.3

(i)

Weight of the package.

(ii)

Marking showing "THIS SIDE TOP".

(iii)

Marking showing the "SLING POSITION".

For all major components, lifting arrangement drawings are supplied.
These should be consulted while lifting these components.

1.2.4

Suitable lifting gear should be selected. The lifting tackles which are
properly certified by appropriate authority about load carrying capacity
should only be used. All tackles should be properly maintained. If the
sling marks are not provided on any of the packing for lifting, the sling

1. Absence of odour from the paper indicates loss of effectiveness. At the time of inspection the case should be opened carefully so as not to destroy the packing material in the process to that it can re re-used. This checking should be preferably done in the presence of BHEL's representative posted at site. The plastic covering should be put back carefully after inspection of the component.should preferably make an angle not more than 30 deg. 1.5 Lifting should be done without jerks and impacts. shall be strictly observed.2. This should not be thrown away as long at it is effective. . and in no case more than 45 deg. which lets off the vapour that prevents corrosion of the parts inside the packing case. Some packing cases may contain VCI (Volatile Corrosion Inhibitor) coated paper.7 On receipt of the equipment check them with the shipping list. 1. while lifting the packing.2. The case should be restored to its original state as -far as possible..6 While handling the packing.2.8 Protective coating applied on machined surfaces should not be disturbed. Silica Gel and such other chemicals kept in the box as desiccants and indicators should also be left in the box. Any omission and damages should be reported back to BHEL immediately. the warnings indicated by markings and inscriptions on the packing boxes such as "HANDLE WITH CARE". "SLING HERE" etc. "THIS SIDE TOP" "NOT TO PUT LOAD ON THE TOP".2. 1. to the vertical.

2 The cases should be arranged in neat stacks away from walls and at least 100 mm above floor level preferably on rail sections.000 kg and above should be arranged in a single tier. 1 . The machined surfaces however are treated with corrosion protective chemicals.1 All these items are generally fabricated from mild steel shot blasted and painted. aluminum foils or . 1.4. These pads should be stored in such a way as to prevent abrasion. dry and well ventilated.2 The babbit metal is quite soft and can be easily scored by ferrous material.3 To prevent distortion the heavy part and other large assemblies should be kept on even platform. 1. The articles weighing 10. Sometimes. upright position indication etc. Adequate gangways are to be left for inspection and cleaning.3. 1.3 STORAGE The equipment should be accommodated in permanent place of storage within a week after arrival at destination. Parts weighting up to 5.4. Small and medium sizecomponents are recommend recommended to be stored on shelves.4 GUIDE PADS 1. As these chemicals are to be removed before assembly. 1.5 meters. scoring etc. These pads must not be stacked one over another. and also so far as possible in the sequence of requirement of the parts for erection.1. on the side exposed for inspection. they are necessarily of temporary nature and can be easily removed. The pads are polished to high surface finish.3.1 The warehouse or the covered area where the equipment is to be stored should be clean.5. in addition to this.5 FABRICATED COMPONENTS 1. 1.000 kg may be piled up to a height of 2. It must have been pretreated with pesticides insecticides against growth of fungus and other micro-organism. It is also recommended to repaint weight.3.1 Guide pads supplied by BHEL have thin lining (2 to 3 mm) of tin base babbit metal chemically bonded to a steel backing.

Small bore pipes are plugged and large bore pipes are covered with flanges. 32630301005 manufacturing specification for water piping. 1. . 1. 1. etc. relays. Jerks and impacts should be avoided in handling these.5. 1. No. For the convenience of site staff a list of major parts and assemblies of hydro turbine with the recommended storage conditions for them is given is Appendix "A". These cases should be fully opened and inspected for any damage on arrival. are marked 'fragile'. Oil and grease do not protect surface adequately. preferably before and after prolonged rainy periods. It is recommended that either a touch up work is done or complete new film of TRP is applied detailed instructions refer Appendix ‘B’. BHEL would be pleased to advice and offer suitable assistance.2 As soon as the components are received at side they should be examined for rupture of preventive (TRP) film given at works. It is recommended that all the instruments are checked for calibration. 32603031006 manufacturing specification for oil piping.8 ASSISTANCE FROM BHEL If any problems arise in handling and storage of all components supplied by BHEL. and not already covered in these instructions.3 It is recommended that films are replaced twice a year. accidental impacts etc. the pipes are pickled and coated with rust preventive coatings. Drg..plywood is used to protect against mechanical damage. The repair and replacement of instruments takes a long time.7 INSTRUMENTS Packing cases containing instruments. Drg. No.6 PIPE WORK Before the pipes and pipe works are sent to site. BHEL do not recommend their use as rust preventives. motors. The instruments should be repacked giving adequate cushioning. 1. but on properly cushioned bases and with adequate protection against falling objects.5. The instruments could also be stored individually without the packing cases. All instruments should be stored in a vibration free area.

. elbows. pump motor unit. couplers. for lubrication unit. Pipe assembly. flooring. Valves.APPENDIX 'A' RECOMMENDED STORAGE CONDITIONS Storage Condition Description of Assembly Fully protected covered area Oil coolers. Battle tray Assembly. hardware NOTE: SEE BOOKLET FOR INSTRUCTIONS ON HANDLING STORAGE AND PRESERVATION OF HYDRO TURBINE EQUIPMENT AT SITE. foundation Bolts-studs-washers. shaft and oil sleeve assembly. cooling Water/oil pipes. flexible housing etc. valves. supports. unions. Semi protected covered area Guide bearing housing.

This can be removed with white spirit.APPENDIX 'B' 2. 2.1.2 Other materials which would be required in the process are: a) Xylol . For site use BHEL recommends the following Temporary Rust Preventives (TRP). following guidelines should be kept in mind.2 Non -Drying Type (Pigmented) BP 55191 This can be applied with brush resulting in soft non-drying film. 2. It would provide protection for a period not exceeding six months. However if any site application is necessary due to long storage.0 PROTECTION OF FERROUS COMPONENTS WITH TEMPORARY RUST PREVENTIVE SYSTEM INTRODUCTION: All components dispatched from BHEL Bhopal would have been given protection against rust by application of one of the following points. a) Non-drying Type (Pigmented) BP 55191 b) Drying Type (Pigmented) AA 55155 c) Drying Type (Black) AA 55154 2. Hence more care is required during storage.1 Materials 2. It would provide protection for a period of 12 months.4 Drying Type (Black) AA 55154 This can be applied with brush resulting in a thin dry film which can be removed with white spirit.1. which can be removed with white spirit Xylol or Toluol. This provides protection for a period not exceeding 4 to 6 months. Because on non-drying nature of the film. 2.3 Drying Type (Pigmented) AA 55155 This can be applied with brush resulting in thin dry film. 2. It is good for outdoor applications.1. it runs the risk of getting wiped off accidentally and exposing that area to corrosion.1.1.

mating surfaces. 4. shaft flanges.8 microns) such as thrust face. moisture etc. 3.0 TRP APPLICATION The application has been classified into four categories viz. 3. Oil Retaining Sleeve.3 Category 'C' . 4. Finally remove the residual acid from the surface with the help of wet cotton otherwise it may cause further Corrosion. A. C&D keeping in view the status of finish and extent of protection desired.. 4. rust.2 Category 'B' Large fabricated items having machined surfaces such as Guide Bearing Support Ring. 0 SURFACE CLEANING Before any TRP is applied on any metal surface the surface should be free from old TRP. 3.4 Wipe off the surface with clean cloth having small quantity of uncontaminated white spirit. In case the surface is still not clean. repeat the process.1 Remove the old TRP with the help of white spirit.2 Remove the rust spots using sufficient quantity of derust solution rubbing with clean cloth. B.1 Category ‘A’ Journal faces. Clean the surface with cloth soaked in water. highly finished surfaces (better than 0. The surface is now ready for TRP application.3 Dry the surface with the help of hot air blower. grease. 3. It may be emphasized that the effectiveness of the TRP is reduced or even nullified if the surface is left contaminated. Vapour Seal Assy. Allow the solvent to evaporate. 4. bearing surfaces of Shafts.b) Toluol c) Mineral Turpentine (White Spirit) d) Derusting Solution (Rust Removal) BP 55193 3.

shall be given a liberal coat of BP 55191 TRP on threaded and non-threaded portion. 5.1. 5. 5. 5. galvanizing etc. galvanizing etc.1 After cleaning. 5.0 PRECAUTIONS 6.3 Fasteners of small size.1.1 After cleaning apply one coat of AA 55155 and allow it to air dry for 12 hours.2 Clean dust from the surface and apply a coat of TRP AA 55154 and allow it to air dry for about 12 hours.3. as Category ‘D’ will have two-coat system of TRP as detailed below.0 TRP SYSTEM OF APPLICATION 5. 6. 5.1 Jobs classified in Category 'A' and ‘B' will have 3-coat system as detailed below. Allow if to air dry for 12 hours.2.1 After cleaning apply one coat of AA 55154 on non-threaded portion and a liberal coat of BP 55191 on threaded portion.4 Category 'D' Small machined components & other components not defined above. 5. 5.2 Apply second coat of TRP AA 55154 on non-threaded portion. 5. having no other protective film such as plating.2.3 Jobs classified. apply one coat of TRP AA 55155 and allow it to air dry for 12 hours inside the store.2. .2 Apply second coat of AA 55154 liberally and allow it to air dry.1.All fasteners and threaded portions excepting in such cases where the job has already a protective film each as plating. 4.3.2 Jobs classified as Category 'C' will have 2-coat system as detailed below.3 Apply second coat of TRP AA 55154 and allow it to air dry. 5. 5.1 TRP should be stirred well in the original container so as to make a homogeneous mixture of its constituents. after cleaning.

6. deposition of dust particles by providing an umbrella of polythene sheet. 6. such as Aluminum sheet. . should be replaced after application of the TRP. the surface of TRP coated jobs shall be examined for any damage.4 Protections. 6. the repair should be done and TRP System applied. given for TRP film. corrosion spots etc.3 During the drying period.6. the wet film should be protected from. 6. plywood etc. The surface coming in contact with the job should be given a liberal coat of AA 55154.6 All materials specified above can be ordered on BHEL.2 Container and brush must be cleaned after application with white spirit before keeping for next operation.5 Normally after an interval of six months.

2. Established centerline and datum shall be made available on steel plates embedded in concrete nearest to respective unit in powerhouse. Grouting shall be stopped when grout material flows out from other grouting holes provided for each space. 2. 2. POWER HOUSE AXIS Customer shall provide axis of powerhouse and elevation. CONCRETING AND GROUTING 2. In case of any deviation corrective action shall be taken. 2.GENERAL GUIDELINES FOR ASSEMBLY AND ERECTION 1. 3.2 For good bonding.8 Grouting wherever required shall be done from bottom upwards as slowly as possible. vibrator must not touch any embedded or machine parts.4 Concreting shall be done in steps / lifts. pedestal of equipments are to be chipped and made even to achieve surface contact for better load transfer to foundation.5 Concrete foundations. 2. 3. MEASUREMENT AND RECORDS 3. 2. measurement shall be taken before and after concreting.3 All surfaces should be cleaned and washed with air water jet. .1 Concreting does not come under BHEL scope of work. However. 2. customer should ensure that following precautions are taken prior to and during concreting.2 For spiral casing with stay ring. 2. Grouting pressure should not be more than specified at relevant places. surrounded by ribs.7 During concreting. old concrete surface should be made rough and if required should be chipped.1 All measurements shall be taken as per the checklists / log sheets of field quality assurance and recorded.6 Recommended setting time is allowed before taking up further works.

5. In case of any damage / shortage. in chalk powder / water container with water replacement every week / water soaked saw dust. 5.3 Final log sheets shall be prepared at each stage of erection work and signed by representatives of BHEL and customer. WELDING 5. UNPACKING AND CHECKING OF PLANT EQUIPMENT 4. 3.3. suitable action in line with QAM/SP shall be initiated to inform concerned agencies. These shall be removed before starting seal welding from other side.2 All rubber products eg. 5. over laps. If the gap is more than 5 mm packing strips are provided to minimize shrinking and welding deformation. Preheating / post-heating of surfaces / stress relieving of weld joints is carried out wherever necessary as per technical requirements. efforts shall be made to achieve best possible results.4 Surfaces are cleaned thoroughly before starting welding. abrupt ridges and valleys.3 Edge preparation is checked / prepared wherever required as per drawing. 5. 4.4 Even though erection tolerances are given. 4. paints etc. are preserved till their use. 5.1 All materials shall be unpacked and checked well in advance of erection work. Cup seals. . Storage and preservation of materials shall be ensured as per manufacturer instructions. 5.6 Proper root gap is maintained for welding to avoid undercut.2 Recommended electrodes are used wherever specified.5 Electrodes are suitably baked in oven prior to their use to 300 C at least for two hours / as per manufacturers guidelines. for a distance of at least 20 mm from weld joint on either side. surfaces must be free from foreign materials such as grease.1 Welding is carried out by a qualified welder. O-rings etc. oil.

5. 5. 5.7 After root run completion of welding dye penetrant testing is carried out and corrective action taken. 5.2 Complete welding in various zones starting simultaneously in opposite quadrants.8.3 After this. gouging / or grinding is done and dye penetrant is carried out. 5.8 Wherever circumferential welding is involved.12 In case welding is provided in pipe works.11 After completion of site welding and grinding painting of effected areas is to be done. 1 is followed for making root run. 5. 5. In other joints skip / step welding as shown in sketch no.1 Mark zone of approximately 300 to 400 mm length as shown. .8.10 All site weld joints of stayring and spiral casing are radiographed or UT done as per technical requirements of concerned drawing. welding may done starting from two or four points and proceed continuously. 2 may be followed to minimize deformation of equipments.8.9 Before starting seal welding on the other side. 5. welding as per sketch no. 5. edge preparation and welding is carried as per drawing requirements. 6.

If not. 7.RUBBER CORD SCARF / STRAIGHT JOINTING 6. 8. 9. TIGHTENING OF FASTENERS 8. it is recommended to apply a thin coating of anti seizing compound i. USE OF LUBRICANTS 7. rectified suitably for obtaining smooth threads. moving or sliding parts. etc. 8. 6.1 During assembly of close fitting parts. Elfy. eg. a thin coat of grease is applied. 6.3 All thread portions and fasteners are proved in advance for checking healthier threads. 8. After fully tightening the fasteners these should be locked as called in the drawing. 6. be sure to proceed symmetrically and uniform.e. Rubber cord of 80% to 90% of the groove area is selected.2 On the other joints of sealing surfaces. In general it is recommended to keep the length of cord 1% less than the actual requirement. 7.4 Clean the ends and make joint with suitable adhesive. The tightening wherever specified should be followed.1 Area of each groove equipments is measured / calculated. 3. molybendenum disulphide or graphite grease in order to prevent scratching or seizing at the time of tightening or loosening. . so that there is no unbalanced tightening in the joint.2 While tightening the fasteners. Anabond.3 Prepare by cutting or / and grinding as shown in sketch no. a thin coat of white lead / holdtite may be applied.2 Cut the cord as per length required including scarf / straight joint.1 On the threads of heavy duty fasteners.

10. 10. check all items of the concerned drawing are available.8 Check for shop dowels. 10.7 Check for special lifting arrangements of assembly / sub assembly. 9. .3 Confirm customers certified centre line and established datum available on embedded plates on the concrete nearest to the pit.2 Check for all technical requirements of drawings to be satisfied at site and ensure their compliance.2 Confirm availability of reference drawings and technical documentation related to the project.3 Check for all concessions /deviations raised at shop if any to be taken care at site and ensure compliance. load grease ports with grease and plug them temporarily. 9. CONFIRMATION BEFORE STARTING ERECTION / ASSEMBLY WORK 10. assembly match mark and axis marking for each assembly. 9.4 Check for all test results of shop wherever necessary.1 Before taking up any assembly. 9. 9. Check for any damaged components and rectify if possible after obtaining concurrence from concerned manufacturing unit.5 Check for PO number.6 Ensure that individual components are cleaned & are free from burrs and scratches.1 Confirm availability of all tools and tackles required for erection works. 9. 9. if any and ensure its availability. 9.10 Blow compressed air to oil and grease ports.ASSEMBLY OF EQUIPMENTS 9.9 Temporary plugs / protections provided should be retained till final assembly. 9.

Oils Dyes Acids Enamel paints and Varnishes etc. Use proper pipe clips. 3. instruments required for erection.4 Confirm availability of all connected equipment’s. be lying in the area where cutting or welding is being done. 8. direct sun rays.1 Check the foundation block outs dimension and locations. 4. hose valves Regulators etc.10. Fire extinguishers. 2. Welding & Cutting 1. Store gas cylinder in well-ventilated place. hot welding slag arc flashes etc. . Welding area should be properly ventilated to minimize air pollution in the surrounding area. 11. No flammable material like Petrol. should be available nearby. Store gas cylinders away from "Sources of Heat" Over Furnace. sand etc.5 Ensure installation of generator assemblies with reference to Radial line of assembly. 9. 10. Acetylene Red hose. 11. 5. 10. Never look at welding arc without using welding dark glass. Oxygen green or Black house. Use proper protective clothings. PREPARATION OF FOUNDATION BLOCK OUTS 11. Ensure against leakage of gas from torch. Periodical checking of pressure gauges of regulator to be done. Ensure proper earthing of work & welding machine to avoid electric shock. B. if necessary carry out chipping of foundations to required dimension and elevation. 7. 6. Use rubber hoses correctly as per coding. welding glass to avoid burn injuries due to welding spatters.

3. Periodic inspection of ropes and safe load testing be done. Lifting of loads shall be started slowly and erratic movements avoided. Use safety appliances like goggles hand gloves. 3. 5. Avoid standing in -front of the wheel or cutting tool. (E) Rotating Small Hand Tools (Like Grinding. Use proper protective clothing. Pull lifts and chain pulley blocks be done. turn buckles. 4. aprons. Guards above moving parts should be in position. 5. Do not subject wire rope beyond safe working loads. While giving signals to crane operator standard signals with which operator is conversant be given by one man. Avoid wire ropes coming in contact with sharp edges while lifting. Do not apply excessive pressure on cutting tools to quicken the process. drilling machines) 1. plan your activity well in advance. 4. 3. Periodic greasing of ropes should be done to avoid rusting and decrease friction. Crane should be regularly maintained as per its maintenance schedule. 2. . 2. 4. 6. For this. Periodic checking of electrical controls and brakes.(c) Lifting Tackles 1. Never stand under heavy loads. 7. gearbox to be done. (D) Cranes 1. Store ropes properly to avoid kinks. Do not keep the load suspended for more time than absolutely required. Periodic testing of 'D' shackles. Grease the wire ropes regularly. 2. 5. 6. whiie in motion.

Tool/Grinding wheels be secured properly. Correct speed be ensured of rotating wheels.6. 7. Never handle any acid or alkali with bare hands and without protection to eyes. Use acid proof rubber gloves. Ensure electric hand tools are free from electric shock. 4. wash off as quickly as possible with a large quantity of clear water and then rush to doctor. Never add water to Acid for making dilute solution. 2. . Whenever there is any acid or alkali burn. Always add Acid to water. gum boots. 8. F. 3. Acids and Alkalies 1. rubber aprons and goggles as per Job requirements.

Stator lowering. Second stage foundation. Test Cylinder & Cone J. embedment & pipes F. (Make up piece) K. Centering. pit liner assembly.V with pivoting & outer Top Cover. Governor oil piping. . Lubrication. Lower Bkt. Feed back Mechanism.T. Lowering of Runner & Shaft assembly with Inner top cover final assy. Cone E. V.V. D. foundation pipes. stator foundation stools W. Centralizing. Spring assembly. Pier nose Liner C. Foundation stools. Auxiliaries & Governor piping T. Welding & Radiography I. X. G. Thrust pad assembly. H. Servo. D. assembly & lowering. B.SEQUENCE OF ERECTION A. O. piping. D. Trial assembly of G. embedment & pipes. Concreting L.S. N. Establishment of C/L & Bench mark. Spiral Casing. Elbow Liner. S. H.T. Pressure Testing & Dismantling Test Cone & Cylinder Runner envelop & Matching Piece. Runner assembly runner & shaft assembly pr. test. Stay ring G. piping & other Auxiliaries. Y. M. U. Lower bkt. Barrel concreting. of Guide apparatus. Rotor assembly & Stator assembly in E. Air cooler assembly.B. R. 1st stage Foundation.

Minimum gross head 18.48 cumecs (overload capacity) 11.206m (future) 4.6. Minimum draw down level EL 511.55m (present) 35. Rated speed 115.60m (present) EL 524.91m 5. Runner diameter 5650 mm 13. Z.256 m (future) 2.50m 8.80 m 14.0 HYDRAULIC AND TURBINE PARAMETERS 2. KPCL – Almatti Dam Power House 2.38 rpm 12. Full reservoir level FRL: EL 519. Spacing between penstocks (already embedded) 15. fixing servo tube. Service bay level EL 504. Maximum discharge 252. Rated head 26.Lowering of shaft after. Penstock diameter (a) Already embedded 7m (b) Extended portion 7.60m (present) 6.16m for power generation 3. Governor time 25 m . Direction of rotation Clockwise when viewed from top 7.1 The hydraulic parameters of the project are as detailed below 55MW 1. Discharge at rated capacity To be furnished 10.6. Type of turbine FULL KAPLAN 9. Maximum gross head 30.

Length of penstock : (a) Already embedded 38. static head) 17. Elevation of deepest : Draft tube point EL 466. OPENING 0 (mm) 555 ± 10  In degree 50° SERVOMOTOR STROKE IN MM 811. Maximum instantaneous 35% pressure rise (% of max.7 .3 CHORD ON OUTER DIA 3890 OF REGULATING 654. Turbine floor level EL 490. Centerline of runner EL 482.42 m 22.90m 25. Maximum speed rise 40% (% of rated speed) 19. Speed droop control : (a) Permanent 0 to 10% (b) Temporary 0 to 100% 21.(a) Effective closing 7 sec (b) Effective opening 15 sec 16.95m (b) Extended portion 47. Distributor centre line setting EL 484.00m 24.72m 23. V. Minimum time required 13 sec for full load acceptance 18. Range of speed 50 ± 5 Hz adjustment device 20.66 GUIDE APPARATUS TECH DATA % GUIDE VANE OPENING 100% G.

Generator Alignment A4. C. Hydraulic Bolt Tensioning. T. Break/Jack piping A3. Oil vapour sleeves & piping. close bearing. Grouting of Stools A13. A20. Governor panel Co2 system etc. Control & Metering panel. etc. MCCs. Oil header assembly A15. All other Miscellaneous work prior to spinning like. UGB A9. Tray work. A8. Lower Rotor. Auto Sequencer panels. Air pipe lines. dowelling etc. SEE. A2. A14. A10.RING A1. Servo tube alignment A6. Loop checking. A11. piping to bearing/Compressor.G. Release lock. MMI. Turbine. A22. Shaft leveling after oil filling. panel. pre commissioning. A19. . checking & termination. Centralizing w. Flooring & Top dome assembly A17. inlet gate. A12.W. LGB. Slip ring alignment. A7. Cabling inside panel A18. Top & Bottom air Guide assembly. Couple Shaft. Transformer. Aux. Guide pad assembly. cabling.r. grouting.t Runner and Locking. Speed sensor Assembly A16. commissioning. Coupling & combined alignment A5. instrumentation. A21.

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Reference Drawings: 02010414201 Pipes & Embedment in I Stage . (a) Draft tube drain pipe. Pier nose liner 25 4. First Stage Foundation Pipe 23 2.Sl. (ii) Check that all the necessary tools. Draft Tube 26 Embedded Parts Embedded Pipe in First Stage (A) Pre-Erection Checks. No DESCRIPTION PAGE NO: Erection of Embedded Parts 1. (B) Erection. (i) Check for availability of all the items as per relevant drgs & bill of material and clean them. equipment & material required are available at site. (v) Ensure proper clamping of pipes so that they remain in the same position during concreting. Field Efficiency test pipes 24 3. (i) Pipes to be erected. Tack weld at minimum 4 points to lock. (b) Spiral drain pipe. (iv) Weld the pipes as per details given in drawing.S plates. (vi) Hydraulically Test the pipes as per Drawing. (iii) Position above pipes as per drawing dimensions & elevations. Blank the open ends of the pipes with M.

0-201-11-14201. . Clamp supports and put covers. No. Field efficiency and discharge measurements are to be made for all 5 units of 55 MW units as per drg. Hand over for concreting. 4. 9. Obtain datum line of penstock. Erect bend pipes and position support. 2. 7. After concreting check pipes for any blockage concreting. Steel pipes to be made at Site. Bends of St. 3. Pressure test pipes as per values given in drawing. Embedded pipes for field efficiency test drg. Mark Bosses on penstock DT liner / spiral casing and weld suitably. 6. 5. 8.Field efficiency test for pipes 1.

2. 02010314201. Fixing of Anchors. Flush grind final run. 5. H.segments and match.Pier Nose 1. Fix foundation bolts and tighten. Match marks etc. Draft Tube Elbow Liner 1. align. 8.t. relevant drgs. Check center-to-center distance and align. : Installation of pier nose liner Drg. Arrange all bottom. erect drain box assembly & connect DT drain pipe & weld. (b) Elevation within ± 2 mm. No. 7. 6. 2. 4. Bolts and Turn buckles lock. tighten. Check Unit Nos. Weld as per relevant Standards 9. 10. . Lower bottom most . Knee liner segments in Sequence. Dye tests the root run. Ref. Check level of pedestal/ Steel supports. Transport D. Tolerance: (a) Vertically 1 .r. Check dimension elevation. 5. 6. Hand over for concreting. Stich welds assembly. left side. Use shims / packing plate for achieving required elevation.mm/metre. Final checking of alignment and verticality.T. 3. top. 7. 4. right side segments and assemble them complying with elevation w. 3. Lower Pier nose assembly using winches wire ropes or suitable crane then check level and elevation.D. matching and then clear for full weld.

align with DT liner and Tack weld. 6. 7. T.t. Reference drawing: Installation of D.T. Drg.r. 0-201-02-14201 Draft tube water path 1-201-00-65602. Hand over for concreting. Release for concreting up to casing of piers for spiral casing and stay ring.11. 3. Lower two top segments of cone and align. Check alignment of cone w. Check elevation of DT cone as per drg. Measure the inner diameter of cone at the top. No. X & Y axis within 2 mm.T. Lower two bottom cone segments. Erection of Draft Tube Cone : 1. Weld the joints as per relevant standards and dye test the root run. then tack weld all turn-buckles. 8. Reference drawing of installation of DT liner Drg. Correct if necessary. correct it. No. 5. 4. : 0-201-01-14201. . 2. Top center of D. cone. cone to be in line with D. liner center within ± 2 mm. If all readings are ok. If it is not as per drg.

(B) ERECTION (i) Transport of stay ring. (vi) Check welds preparations for site welding joints as per drawing.SL. Conduct . (v) Establish center line (x. STAY RING 29 2. (viii) Seal welding of Joints to be done as per drawing requirement. so that stay ring pedestal are resting on the stool. (v) Ensure Tightness of joints 0. PIT LINER 32 STAY RING (A) PRE ERECTION CHECKS (i) Check for availability of all the items as per drawing. Align center & level with respect to station. using hydraulic Jacks/Mechanical Jacking screws. RUNNER ENVELOP 31 4. y Axis) & Datum elevation given by the civil wing. (ii) Assemble in service bay and heat and tighten the Joint bolts to achieve elongation as per drawing. (ii) Check for any damage during transportation & repair if necessary. (iv) Lower the Stay ring on stools. (iii) Use the sling given as per drawing and lift. (iii) Check all the pier details as per drawing. (vi) No step at joints on top & bottom machined surfaced after joining. Check radius at top & bottom machined bores.NO DESCRIPTION PAGE NO Erection of Foundation Parts 1. (iv) Check & prove threads on joint bolts & nuts. (vii) Check locking of Joint bolts & Nuts. Center Line. SPIRAL CASING 30 3.05mm feeler gauge should not go.

(ii) Check for any damage during transportation & repairs if necessary. complete the sealing run.m (ii) Match the spiral members with top & bottom contour of stay ring & center line marked on spiral member with reference to center line of stay ring (± 2mm). (viii) Place test cone and weld with spiral inlet. (vii) Lower the test cylinder and fix it in position. (B) ERECTION (i) Assemble the spiral segments as per drawing & ensure that gap at joints in axial or radial direction is 2 to 5m. . (v) Back gouge. (i) Check for availability of all the items as per drawing. (iv) Dye check the weld seams for any surface defects in the plate. No.NDT tests as per drawing requirement. bolts & jacking bolts & other hardware. (vi) Radiograph and ultrasonic Test for all butt Joints to be carried out as per drawing requirement. : 02020114201 Log sheet = L-02 SPIRAL CASING (A) PRE-ERECTION CHECKS. (ix) Carry out the Hydraulic testing of spiral casing at pre test pressure and time as given in drawing. (iv) Check weld preparation for site welding joint as per drawing. (iii) Weld the spiral segments as per technical requirements given in the drawing. grind & dye check for seal run. (iii) Check and prove threads on holding down. Tolerance : Ref drawing : Installation of stay ring stay ring installation Drg.

(xi) Complete the installation of holding down bolts. Check diameter. t . Pre Erection Checks. r . Runner Envelope to be lowered. Welding of make up piece with D. welding and NDT of inlet pipe as per drawing. v. & lock all the hardware. after lowering for Ist out before stay ring. T. 02020214201 2) Arrangement of spiral testing 02025214201 3) Installation of inlet pipe to spiral casing drg.Drawing : Log sheet L-02 Installation of Stay ring. remove test cone & test cylinder. 02020414201 Ref. wedges. Fastening. (xiii) Carry out erection. i. axis of stay ring and check diameter. B. . Centering w . No. Erection. iii. Test. 2. Log sheet L-03 Installation of Stay ring & Spiral inlet pipe Runner Envelopes A. (xiv) Recheck the alignment leveling of stay ring before handing over for concreting 1) Installation of spiral casing drg. ii. No. Trial Assemble two halves at service Bay. anchoring and welding with stay ring. (xii) Check the leveling & stay ring. iv. 1. cone & Runner envelope. Dye testing of seal welding of joint flange to be done. anchors.(x) After successful completion of Hyd.

vi. Recheck: the centering of Runner envelope after concreting. 02020614201 Log sheet L-04 Installation of runner chamber . Runner envelope installation Ref Drawing no. Spider assembly to be carried out before concreting. as per requirement of drawing. vii.

02020714201 SL. per meter 2. 4. DESCRIPTION Runner assembly in Erection Bay. No.PIT LINER ERECTION A. 1 mm. Top dia of pit liner (± 5 mm) 3. LOWER THE PIT LINER SEGMENTS 1. servomotor 10. of G V. Installation of pipes / Pipes sleeves for routing of air. Ref Drawing: Installation of pit liner Drg.V with outer Top Cover & dismantling 5. Ensure placement of sufficient sleeves for routing cables etc also. Installation of Regulating Ring 9. Guide Apparatus Assembly 6. Installation. testing & Testing of Cone assembly 2. Welding of anchor plates. Guide Bearing 11. Trial assembly of G. Welding to requirements as per drawing. Shaft seal PAGE NO. water and other pipe lines. Outer Top Cover assembly 4. Also check that embedded pipe carrying in this state of concreting are installed and the free ends are blanked off by welding metal plate. . Lowering of runner assembly with inner top cover &final assembly & centering 8. Pivot ring assembly 3. Runner & shaft assembly with outer top cover 7. NO 1. 5. The mechanical surfaces for fixing the servo motors are equidistant from X & Y axis (with tolerance as per drawing) & are vertical.

2. h) Check that the locking of Bronze Bushes are as per drawing. report to unit if any abnormality is noticed. Check the match markings during dismantling (if the runner is received at site in assembled condition). Oil-Header 13. sliding blocks and other components against any scratch. During reassembly of runner as per drawing. plugs and valves are as per technical requirements/details of drawing. washers. . f) Check correct joining and assembly of rubber cords and other seals. servo motor cylinder. 3. check the following: a) Ensure usage of proper / suitable settings for lifting & twining of runner. Installation of Metering Instruments RUNNER ASSEMBLY 1. sealing. b) Check the machined surfaces of piston. 5. e) Check the grooves and rubber cords for their sizes. k) Assemble runner shaft and servo tube with runner as per drawing l) Elongate coupling bolts as per the values mentioned in the drg. j) Check that the locking on laterships. 4. Governing Equipment 14.12. i) Check that the pre stressing of fasteners is done as per drawing reference. g) Check the free movement of sliding blocks. cup scales etc are in good condition. Perform overhauling internal checking of runner as per drawings. d) Check that the threaded holes and fasteners are not damaged. c) Check that the rubber items such as 'O' seals. Perform visual inspection for any damages. dents etc. Check availability of all materials as per drawings.

No. n) Perform testing of the Runner as per test procedure technical data provided in the drawings supplied by manufacturing unit. 02040714201 3. Drawing to be referred 1. Arrangement of all tubes of runner servomotor drg. Testing devices for runner & shaft drg. No. it should be as per drawing value. Tools tackless for runner shaft drg. 2050314201 5. 02045114201 2. No. 02050114201 4. L-05. 02045214201 6. No. Runner assembly drg.m) Measure and record the clearance between runner hubs & blade. Log sheets: 1) Elongation of fitted bolts between runner & shaft L-06 Test certificate for KAPLAN runner assy. . No. Shaft arrangement drg.

Runner received in site in dismantled condition. piston rod. fully assembled or partly assembled and partly loose depending on its overall size / transport limitations. 3. 2. KAPLAN RUNNER 1. The loose components may be runner servo tubes. While remaining bottom cone ensure match mark is there. Carry out assembly of runner blade with cup seals as per instruction given in drg. runner blade received at site separately. Hyd. to ensure trouble free operation. Remove bottom cone & perform through checking inside. hydraulic testing of completely assembled runner at site in accordance with technical requirements. 7. close to open & open to close). turning mechanism. Carry out trial lowering of assembled runner in to the runner chamber if called up before its assembly with shaft to check and ensure clearances between runner blades and runner chamber with runner blades pulled out. Fix bottom cone as per match mark & perform tightening & locking. 3. 4. OVERHAULING ASSEMBLY 1. overhauling of partly assembled components. Runner of a Kaplan turbine is dispatched to site. Assemble any loose components & carry out tightening of fastener. bottom cover etc. In the event of clearances being less than those specified in the drawing. 4. Turn the portion of the runner & lower it over the platform made for runner blade fixing. 2. Testing A. Shaft assembly.e. cone and other hardware. Place runner on pedestal. Check all the materials as per drg & all tools available for carry out overhauling. .RUNNER ASSEMBLY Overhauling. piston. runner blades. Carry out dismantling. locking called in drg. Partly assembled runner comprise of hub. 5. correction is done either by grinding the tip of runner blades / runner chamber in the complete zone of runner blades operation (i. B. 6.

6. Place the runner leveled on stools / wooden sleepers. Prepare FQA log sheet for elongation tightening & completion of runner shaft assy. 3. feeler gauge will not pass.B.03 feeler gauge. 7. Maintaining accessibility with shaft suspended. 10. 2. 9. Check the mating surface of turbine shaft & runner for trueness. Insert the lower part of servo tube in shaft bore before runner shaft assy start. Check and prove bedding of guide bearing pads with guide bearing journal of shaft. ASSEMBLY OF TURBINE SHAFT WITH RUNNER 1. 8. In the event of correct assembly. Check & ensure the holes of coupling bolts in runner & shaft and coupling bolts are as per drg. acid pickling. tighten to required stress / elongation as per technical requirement & lock the nut. . lower the shaft and carry out assembly of shaft with runner. 4. Install all coupling bolts. Carry out locking of fasteners and dowels as called for. Install O-seal. lower and assemble servo tube with piston rod coinciding match marks and using dowels. C. Prepare shaft in line with general guidelines and check trueness of all machined surfaces. Check soundness of runner shaft assembly joint with the help of 0. neutralization and oil rinsing interiors of oil servo tubes. Instructions for bedding of pads) before runner shaft assy start. 12. Turn the shaft to make it vertical along with servo tube (runner servo tube is suspended with chain pulley blocked to the same crane hook connected to shaft). Cover the open end of servo tube temporarily to avoid entry of foreign materials in to the system. Carry out cleaning. 5. with shaft in horizontal position (Ref. coinciding the match marks. Transfer and lower the shaft on to runner. 11.

through the cup seals of runner blades. HYDRAULIC TESTING OF RUNNER & CHECKING LEAKAGES 1. Install PP set. tackles & erection device for runner & shaft 4) 02050314201 Arrangement of oil tubes of runner servomotor 5) 02045214201 Testing devices for runner & shaft log sheets : L-05.D. Note : Oil leakage is not permitted. Note : Oil leakage is not permitted. through the cup seals of runner blades. 1) 02040714201 Runner assembly 2) 02050114201 shaft arrangement 3) 02045114201 Tools. carry out locking of all fasteners as called in drawing. If possible. Carry out laying and connection of pipes as per the scheme of testing supplied by the manufacturer. 2) Lower the complete assembly in to runner chamber and carry out assembly of top cover using seals dowels and fasteners etc. HP compressors and commission them / alternately install these equipment’s provisionally for testing of runner. pressure vessel. INSTALLATION OF RUNNER SHAFT ASSEMBLY 1) Runner shaft assembly is lowered along with turbine top cover. Testing be continued for the duration as indicated in drawing. . 5. After successful testing. L-06 E. Runner shaft assembly is supported on top cover with a suitable supporting bracket fitted at the seat of turbine guide bearing. No. 4. Carry out testing of runner in the manner stipulated in drawing and check leakages through sliding mechanisms. 3. Reference Drg. 2. Lower runner shaft assembly further to make GB skirt rest over the bracket. Turbine guide bearing skirt rests over this bracket.

Drg. . tackles & erection devices for runner & shaft Log sheet : L-07 C.3) Carry out leveling at turbine shaft flange and centering of runner with runner chamber. No. : 02045114201 Tools. Ref.

for erection of pivot ring. 2) Perform visual inspection for any damages. Report to manufacturing unit if any abnormality is noticed. : Guide apparatus 02030114201 . 9) Align & level pivot ring as per instructions given in drawing. for their assembly. if any. 3) Check the matching surfaces of pivot ring for any burr / foreign materials. Grinding to be done if required to achieve the level. and lower them over the cleaned resieng surface. Clean. 10) Lock the bolts as per drawing requirements. Reference Drgs. 4) Ensure availability of proper tools slings etc. 7) Lift the assembled pivot ring.PIVOT RING INSTALLATION 1) Check for the availability of all the materials as per drawing. 6) Lift the pivot ring individual segments and lower them on wooden pegs kept on the runner envelop / stay ring. 8) Tighten the holding down bolts. 5) Check the runner envelop flange level.

4. Sling the assembly and lower on speed ring flange as per match mark & support / hang suitably. the outer top cover may be lifted as per drawing and position Guide vane assembly. Grind them if necessary to achieve drg. Reference Drg. Put H. : Guide apparatus Drg. During final assembly of guide vane also.V. 2.  Check the leveling of speed ring top flanges and groove area. The segments are to be lowered in pit as individual segments. Assemble all four segments of outer top cover inside turbine pit. Match holes of speed ring flange with that of outer top cover.  Perform visual inspection report  Ensure availability of T & Ps.ASSEMBLY OF OUTER TOP COVER Outer top cover is in 4 segments.D.V. No. Trial assembly to be done by lowering guide vanes using lifting tackles. The procedure of Trial assembly is given in following pages. Lock the bolts as per drawing requirement. Value. During lowering of G. 1. 5. Check availability as per drg. 6. Final assembly procedure is also given in following pages. Clean joint flanges and check for smoothness.S. 3. bolts and tighten. are lowered after lifting Top cover in site using hooks provided in barrel. the G. : 02030114201 .

4) All flanges and threaded holes of stay-ring are cleaned and surfaces deburred. 3) Turbine pit is cleaned of all civil materials and is painted. 2) Generator barrel is painted except stator. lower bracket foundations completed. 5) Horizontality of stay-ring flanges checked and corrective action executed wherever required. and upper bracket foundations. lower bracket. 6) All components of guide apparatus and erection devices as per drawing are received. .ERECTION OF GUIDE APPRATUS PRE-ERECTION CHECKS 1) Generator barrel is cleared of all civil materials and chipping of stator.

FINAL ASSEMBLY OF GUIDE APPARATUS PRE-ASSEMBLY CHECK 1) Dismantle and remove all the components assembled for trial assembly. Lift the top cover precisely leveled with the help of turn buckles and crane and lower it on stay-ring. corrective action is taken wherever required. 4) Assemble lower ring-using dowels to coincide with XY match marks of stay-ring. 12) Bring all guide vanes to close position. 15) Complete reaming. 13) Carry out bedding of guide vanes and correction if need be. 8) Assemble four upper guide vane bush housings. 3) Depending on type of design. 2) Remove preservatives and clean all the components of guide apparatus and prepare the components for assembly as per general guidelines. top cover positioning and dowelling. lower ring. 10) Install alternate holding down studs of top cover and install all upper guide vane bush housing (thin layer of grease on guide vane journals and bush housing before installation). 5) Centre the pivot ring bent runner envelop 6) Install all holding down bolts of lower ring and complete tightening. While tightening the nuts of holding down studs till tightening of all nuts of top cover is finally completed. 90 degree apart on top cover. trial clearances and free turning movements of guide vanes are as per technical requirements and to establish.TRIAL ASSEMBLY OF GUIDE APPARATUS 1) Even through the guide apparatus assembly is proved in the manufacturer’s unit. In case of deviation from the drawing requirements. lower ring may be assembled finally with seals. 11) Check and ensure free turning of all guide vanes. 14) Lower inner top cover & align it. to check and ensure the clearances of guide vanes with top cover at leading and trailing edges are as per drawing requirements. 2) Check the rubber cup seals and O-seals do not carry any cracks and are not de-shaped. 9) Position the top cover using dowels and reference match marks. doweling of lower ring and inner top cover & outer top cover. Note : Thin layer of grease is applied on bearing and guide vane lower stem before installation. 3) Install cup seals and retaining rings on lower bush bearing of guide vane . 7) Lower and position guide vanes as per number match marks.

15) Install connecting rods of servomotors with regulating ring and carry out pre-stressing of guide apparatus mechanism (refer instructions described separately). the retaining ring shall be suitably machined. 11) Install regulating ring and servo motors (refer instructions for installation of servo motors of different variants. Note : After final assembly of guide apparatus. cm or as indicated in drawing. described separately). 10) Check and ensure centering of runner w.check gap between top cover & stay ring flange by 0. the runner shaft assembly is installed in a lower position from designed level by an amount 3-4 mm more than the spigot height of the generator shaft flange. its causes must be investigated and removed. (ensure bush house installation with reference to grease port for pipe connection) 7) Guide vane should move freely when turned by one person by using spiral spanner supplied as erection device by the manufacturer. 5) Install rubber seal of top cover on stay-ring & complete the assembly of top cover with stay ring using dowers pins & fasteners ( to ensure proper assembly of top cover stay ring . 4) Lower guide vane in position.r. 6) Assemble guide vane bush houses with seals and check free turning movement of each guide vane.t. 9) To facilitate alignment of generator.1 mm Leveling with 0. In case guide apparatus fails to turn at this pressure.03 mm/met. The complete mechanism should turn freely at oil pressure not more than 5 kg/sq. After installation of bush. 13) Check free turning movement of all guides vanes from full close to full open position.which should not pass).and ensure that retaining ring does not interfere with lower collar of the guide vane. 12) Install link mechanism and adjust guide vane end clearances. bedding clearance and clearance between lever and lever stopper / collar. Note : Allowable tolerance in centering 0. grease and lubricate all bearings and check for easy turning movement of guide apparatus mechanism by applying oil under pressure in the servo motors. 8) Lower runner assembly with inner top cover runner shaft assembly. In case of interference. Lower labyrinth on lower ring is within the specified limits. PRE STRESSING OF GUIDE APPARATUS MECHANISM . 14) Position regulating ring to close of guides apparatus complete centering and provisional locking.03 mm feeler gauge . 16) Prepare FQA log-sheet for completion of guide apparatus assembly in accordance with field quality checks.

Complete locking of turn buckles with lock nuts. for opening and closing is as per design requirement (for Francis turbine) Check relationship of guide vanes v/s servomotor. 8. Movement of piston so measured is the tightness required in the guide vanes. 2. forward by 15 mm by adjusting the length of connecting rod with turnbuckle. according to drawing instructions on servo motor piston for closing and measure the amount of movement of piston.1 The stopper of servomotor moves freely in and out.e. Release the oil pressure and install the piston of both the servomotors from the end support at a distance of tightness value measured. check that regulating ring is not disturbed and remains in the closed position of guide apparatus. 7. Apply oil pressure.03 mm feeler gauge. when measured with 0. In closed position of guide vanes.3 Guide apparatus servomotor opens to its full stroke. 7.2 Plot the graph from the values obtained check that the curve nearly matches with the design values. back by same amount i. 8. INSTALLATION OF GUIDE VANE SERVO MOTORS A) Pre-erection checks including overhauling and re-assembly In case servomotors are not put into service within 12 months from the date of its dispatch. Governor and guide vanes v/s runner blade. 1) Dismantle the servomotor after proper match marking of all . bring the piston of servomotor with stopper. KINEMATICS OF GUIDE APPARATUS 8. 5. Tightness in guide vanes is determined in the following manner upon the readiness of oil pressure system. Tighten lock nuts of turn buckles of both the connecting rods. 6. For this following procedure may be adopted. 3.2 Clearance between adjacent guide vanes all along their height is 00. Take the piston of servomotors without stopper. 7. governor and completion of working mechanism in all respects. when the oil pressure is applied for opening of guide apparatus. Apply pressure for closing of guide apparatus and check that. 7. the same may be over hauled. 15 mm in the similar way. governor for closing is as per design requirement (for Kaplan turbine).1. While doing this.1 Upon completing governor adjustment and readiness of starting the machine check relationship of guide vanes v/s servomotor and governor. 4.

2. piston touching the respective cylinders ends).02 mm/m) on piston sleeve level should be achieved with 1 division. Couple mounting plates with servomotors using studs & nuts. 10. B) INSTALLATION 1. 3. The connecting rods of servomotors to be assembled with regulating ring keeping the guide apparatus fully closed. D. (3) 0203111420 for technical requirements.components / joints. (2) 02030314201. taking care to keep the slot portion of piston towards oil ports. Align both the servomotors to drg. 7. used for pressing the piston rings. If necessary clean and dress with triangular smooth file. 3) Clean thoroughly all parts and inside surface of piston and cylinder with solvents like diesel / petrol check the surfaces of piston. No.V. Check vertically. Check the interference of cup seals I. Dimension. with sleeve. 4) Use new cup seals and prepare “O” ring if assembled ones are worn out and if replacement is necessary. piston rings. Lower servomotor stopper in position to lock the movement of piston. (1) 02030214201. Lubricate cylinder surface profusely with turbine oil as soon as piston rings have entered the cylinder remove clamp. keep 25 mm gap between piston rod and connecting rod. Maintain the distance 1985 of G. & after checking the opening and closing of servomotor and checking the seals are intact. 4. cylinder. Locking of nuts to be carried out only after satisfactory hydraulic testing. Assemble the piston rod and connected rod initially.e. Keep the piston rods of both servomotors in fully closed position (i. . Lower both the servomotors in their respective position. 2) Check the cup seal “O” rings of servomotors for any cracks or damage. for any scratches. 9. 8. servo cylinder (Not of piston rods / connecting rods) and level the servomotor. Push / pull the servomotor piston fully in/out. bushes etc. Level the servomotor precisely (horizontal) check level by precision block level (accuracy 1 Div = 0. 5. Now if the gap between mounting plate and plate of pit liner is less than 3mm weld mounting plates directly to pit liner without using strip. 6) Insert the piston assembly in the cylinder in vertical position. Also refer the drg. Fasten the covers by tightening the studs and nuts. 7) Assemble the cylinder cover using cup seals. 6. Check and clean the base plates mounted on pit liner. Check the threads of piston rod. Fasten the cover with stud nut. 5) Assemble the covers using “O” ring.

regulating ring (within 1 mm). Center line servomotor is parallel to Y axis and at a distance as specified in the drawing (within 1 mm).r. TOLERANCE: 1. 12. Ref. servo stroke indicator scale.otherwise they are to be welded using strip as shown in the drawing no. Check the guide vane bedding its nut as per drg value correct it with both the servomotor operation. V. Also check and set if necessary the G. L-10 02030314201 GV servomotor RH opening of GA depending on 02031114201 Installation of GV servomotor run of GA servomotor piston .t. 11. 2. Drg. Elevation of servomotor w. 02030214201 GV servomotor LH Log Sheet No.

6.0 GUIDE BEARING.
A)
i)

Pre-erection.
Thoroughly clean all parts and joint faces of bearing oil sump. Use
engineers blue on one face, tighten the joint faces and check the
bedding. If necessary scrap the face. Filler gauge can be used to find
out the gap.

ii)

Clean the bearing pads with solvent like petrol and white spirit. Check
their bedding with the bearing journal of the shaft. If necessary
Scrapping can be done. Also check the bedding of Disc. Check that
stud has spherical curvature where it is pressing the disc.

iii)

Measure resistance of RTD with standard mercury Thermometer on
heating as well as on cooling Cycle. Use suitable oils both during
above Calibration.

iv)

Check the groove sizes and prepare rubber-sealing Ring.

v)

Check the working of oil level indicator in Separate oil container out
side.

vi)

Apply liquid sealing compound (hold tight at joint faces of the Bearing
oil sump. Bottom ring)

B) Erection (before alignment)
(i)

Fix. studs called in guide apparatus drg. Assemble bearing housing
with dowel and pins, bolts nuts washer, O-seal respectively, taking care
that no step at any joint.

(ii)

Install the rubber ”o" rings and position the bearing housing matching
with unit axis marked on the top cover and bearing housing.

Center the center piece with respect to turbine shaft journal (with runner at
centre) Tighten nuts and washer.
(iii)

Assemble the pipe assembly in their respective position. Suitably blank
it for testing with kerosene for any leakage through “O” rings. Remove
the kerosene after testing.

(iv)

Fix studs with holdtite. Assemble the two halves of bearing housing,

Match with axis and complete the assembly of bearing housing.
Bearing housing should be checked for any leakage.
(v)

Cover/protect the bearing from dust/foreign material till alignment is
complete.

C. DIRECTION (AFTER ALIGNMENT)
Note: After the unit axis alignment is completed, runner centered with
respect to runner envelop and rotating parts are lying vertical and
locked. Final boxing up of turbine bearing can be taken up.
1. Clean the inside area thoroughly with compressed air/Vacuum cleaner and
moping cloth.
2. Lower the bearing pads and stud and nut in their respective position (i.e.
with respect to RTD & MST connections). Apply molysuff or any other anti
thread seizing grease on the thread of stud. Insert disc and bring stud near
to disc to avoid falling.
3. Install 2 Nos. dial indicators at 90° apart to measure/check the shaft
movement. Set these dial indicators to zero value. Press all the pads so as
to touch the shaft journal.
4. With all bearing pads touching shaft, set the gap of 0.15 to 0.2 between
the disc and stud (Spherical surface) and lock the nut. Re-check the above
clearance.
5. Mount RTD and MST (already calibrated outside).
6. Install bearing cover with all other items as per drawing with "O" seal,
Gasket etc.
7. Assemble bearing oil level controller with its probe.
8. Record all the readings achieved in log sheet.
9. Fill the turbine oil in bearing and centrifuge the oil till it is clear (APPROX)
1 5 TO 20 circulation’s as a guide line
Tolerance: Centering of Bearing Body w.r.t. Shaft with in 0.2 mm.
Ref. drawing: 02060114201

Log sheet L-11

Arrangements of guide bearings

Clearance of Guide Bearing

TURBINE SHAFT SEALING
1. PRE-ERECTION
1.1

Dismantle components of shaft sealing, clean them thoroughly and
check the joint faces for flatness and absence of damage.

1.2

Assemble housing of isolating seal, place the isolating seal and housing
and cut the extra length of seal. Test the isolating seal by air as per
chemical requirements of drawing and confirm expansion of seal under
air pressure.

1.3

Check and grind the top surface of cups, if any projecting over and
above the surface of ring supporting the working seal.

2. ERECTION
2.1

Assemble base plate / housing of isolating seal with top cover along with
“O” seal, maintaining clearances between rotating and stationary parts
as called in drawing (use liquid compound / hold tite at the joints of
housing).

2.2

Install and join isolating seal using suitable adhesive such as anabond /
elfy.

2.3

Place the cover plate in position and assemble it with housing.

2.4

Install cups and lip-type rubber working seal and join it with suitable
adhesive and complete the assembly of cover plate.

2.5

Install upper working seal, join and assemble cover plate.
Note:
i)

Joints of rubber working seal are made taking into account the
direction of rotation of the machine.

ii)

Clearance between rotating and stationary parts is maintained by
grinding wherever necessary.

2.6

Carry out drilling, reaming, doweling of turbine shaft sealing frame with
top cover.

The runner feed back system & the indicator showing the position of runner blades are also mounted on the oil header. generator shaft and a oil guide / deflector installed on shaft.1 Oil header is intended to supply the oil under pressure from oil pressure unit to runner servomotor through a set of concentric pipe lines installed in turbine. 4.4 Check and record the diameters of bush and pipe line assembly. 4. The leakage from the runner passes to pressure pumping set through the bore of turbine. Check oil deflector items machined surfaces are true and check level and surface finish exciter shaft for trueness (where oil deflector is assembled). . generator shafts. in the oil header bush is smooth. No.1 Check individual component of oil header is prepared to technical instruction.3 Place oil header assembly upside down and ensure the movement of pipe line assembly. OIL HEADER (REF SKETCH) 3. Oil pressure for opening closing of runner blades is supplied through main slide valve of runner installed in HMC of governor. Drg.2. shaft and inner top cover in erection bay check horizontality of the upper flange of oil tube (lower).2 Check surface finish of pipe line assembly as per drawing requirement and there is no ovality on diameter at location where it passes through the oil header bush. Oil header is assembled with runner shaft logged after alignment & center of runner.1 After assembly of runner. 4. 4.7 Connect cooling and pressure water piping Ref. 5. PRE ASSEMBLY 4. ERECTION OF OIL TUBES & OIL HEADER Following sequence of activities to be followed for erection of oil tubes and oil header: 5. Upper flange of oil tube (lower) should be parallel to turbine shaft coupling face. : Arrangement of shaft sealing 3.

check throw of central pipe and pressure box.6 Lower and assemble generator tubular shaft with generator shaft. 6 and pressure box is preferably 75% of the diametral clearance at pressure box bearing. 4. 5.8 The allowable value of throw for point no.5 Assembly oil tube (upper). 5. centralize oil bath to get the uniform labyrinth clearances.10 If the throw is more than the value mentioned in Para 8 & 9 above. 5. check the horizontality of its top flange and throw of spigot. check the horizontality of flange of middle tube and throw of its spigot. 5. correction to be done in respective flange face by suitability scraping or using shims taking care of ‘O’ seal grooves.2 Lower the assembly of runner. 5. 5.11 Assembly oil bath and oil guide as per drawing.7 Lower the assembly of central pipe and pressure box. below generator shaft to facilitate coupling of tubes. 5. check throw of spigot in generator tubular shaft and horizontality of top flange.3 Insert middle tube inside generator shaft in erection bay and then lower in the pit keeping oil tube projected by 200 mm approx. 5. and in no case it should exceed the value of diametral clearance.9 The allowable value of throw for central pipe is preferably 75% of the diametral clearance at central pipe bearing.4 After connecting middle tube to lower tube and assembly of generator shaft with turbine shaft. 5.12 Lower oil header body carefully in balanced condition taking guide from central pipe in such a way that there is no radial pressure or bending effect on central pipe. After assembly with upper tube. 5.5. and in no case it should exceed the value of diametral clearance. loosen the spigot suitably by grinding and assembly body to oil . If the spigot between body and oil bath does not match. 5. shaft and inner top cover along with oil tube (lower) in the turbine pit (preferably after testing of runner on erection bay).

3. 4. After assembly of Runner. if required replace it. (iii) Prepare all the "0" seals and check for damage/crack. After connecting middle tube to lower tube and assembly of generator shaft with Turbine shaft check the horizontality of top flange of middle . shaft and Inner top cover along with oil tube (lower) in the turbine pit (Preferably after testing of Runner on erection bay). (ii) Clean all the components. OIL HEADER AND OIL TUBES (A) Pre-Erection. rotate the machine at very slow speed for checking any fouling between stationary and rotating components. dowelling of oil header body and oil bath to be carried out.13 After checking free rotation and stroking of oil tubes. 5. 1. Insert Middle tube inside Generator shaft in erection bay and then lower in the pit keeping oil tube projected by 200mm approx. (i) Check that all items are available.bath. below generator shaft to facilitate coupling of tubes. 5. Upper flange of oil tubs (lower) should be parallel to turbine shaft coupling face. GUIDE LINES FOR ERECTION OF OIL TUBES AND OIL HEADER OF VERTICAL KAPLAN TURBINES Refer enclosed Sketches No. Following sequence of activities to be followed for Erection of oil tubes and oil header. 2. HTE/SK/001 and HTE/SK/002. Shaft and Inner top cover in erection bay check horizontality of the upper flange of oil tube (lower).14 In extreme position of runner blade stroke (fully open and fully close). Lower the assembly of Runner.

After checking free rotation and stroking of oil tubes. and in no case it should exceed the value diametral clearances. Assemble oil tube (upper). of the diametral clearance at pressure bob bearing . 12. After assembly with upper tube. 14. 11. check throw of spigot in generator tubular shaft and horizontality of top flange. check the horizontality of its top flange and throw of the spigot.tube and throw of its spigot. value of throw for central pipe is preferably 75%. 7. and in no case it should exceed the value of diametral clearance. Assemble oil bath and oil guide as per drawing.6 and pressure box is preferably 75%. 10. of the diametral clearance at central pipe bearing. 9. If the throw is more than the value mentioned in Para 8 & 9 above. 8. Lower and assemble generator tubular shaft with Generator shaft. Lower oil header body carefully in balanced condition taking guide from central pipe in such a way that there is no radial pressure or bending effect on central pipe. . If the spigot between body and oil bath does not match. correction to be done in Respective flange face by suitably scraping or using shims taking care of "O” seal grooves. dowelling of oil header body and oil bath to be carried out. Lower the assembly of central pipe and pressure box. The allowable. . In extreme positions of Runner blade stroke (fully open and fully close). The allowable value of throw for point no. 5. check throw of central pipe and pressure box. 4. 13. Grinding can be carried out since there are 4 Dowels of 16mm in addition to 16 studs of nuts of M20 for holding the body with oil bath which keep the joint tight even in running condition job the Machine. rotate the machine at very slow speed for checking any fouling between stationary and rotating components.5. centralize oil bath to get the uniform labyrinth clearances. 6. loosen the spigot suitably by grinding and assemble body to oil bath.

HTE/SK/001 & HTE/SK/002 Tolerance: 1. (v) Check that motor is free. . if necessary. Centering of Center tube . Centering of oil Header . CHANGES DUE TO REVISION: NIL 16. Ensure no gap exists between supporting brackets and concrete. (iii) Check that all the blanking flanges are intact. (iii) Hydro mechanical cabinet & runner control mechanism. (ii) Chip the concrete to make it supporting surface level.15. ENCLOSURES: Sketch No. Pressure Pumping set (A) Pre . Grease the bearings. using eye bolts in fairly levelled condition (ii) Install the P. Ensure sides of these pockets are slightly rough for proper bondage of concrete. (iv) Feed back mechanism. Set assembly on 4 equal wire Ropes. (iv) Fill the pockets by concrete and allow it to cure. (ii) Pressure Receiver. GOVERNING EQUIPMENT (i) Pressure pumping set. Check the elevation at 4 places. Set as per drawing dimensions. (B) Erection. bearing is sound. (vi) Do not run the motor with out oil in the tank. (iii) Check the vertically by plum bob at pipe flanges.15 (By rotational check). (i) Lift the complete P.erection (i) Check all the pockets of foundation are as per drawing.1 mm 2.P.within 0.P.within 0.

(i) Check that foundation pockets are as per drawing. (ii) Check the verticality by pump bob on two planes. Hydro Mechanical Cabinet & Runner Control Mechanism (A) Pre-erection. Lift the pressure receiver in balance condition and assemble it on the (i) foundation bolts. (B) Erection. (ii) Remove manhole door and inspect for any rusting from inside surface or foreign material during Transportation. (ii) Use leveling screws to leveling screws to level and achieve elevation as per drawing. (ii) Clean the component cleanly. (iii) Check the verticality of the cabinets by plum bob and also check level.(ii) Pressure Receiver (A) Pre-Erection . Care to be taken that angular position of the mountings are as per drawing. (iii) Check the location and size of the pockets are as per drawing dimension. . Check the paint condition from inside. (i) Install the hydro mechanical and electrical cabinet as per the drawing. Pressure test the receiver with air and check leakage through any (iv) fittings. Place the manhole door in the position if required replace the gasket. (i) Check all the items for any damage/breakage. (iii) Mount all the fittings on receiver and prevent them from any damage (Glass parts/pressure gauges). Align the pressure receiver as per drawing dimension. (iii) (B) Erection.

Ref .  Arrangement of PP set - 02210114201  Arrangement of pr. Force. Note :After installation of above panels dust/ moisture in this area should not be allowed. : Drg. all precautions like chipping/cleaning in the surrounding are to be taken prior to installation of these cabinets. DTTT’s. Touching of wire rope with any bracket. (iv) Movement of wire rope should be free. RTDs. is not allowed. before installation or as called in drg. tube etc. (ii) Wire rope be pre-stressed to 300 kg. of the rod for free movement of kinematics. Gauge. Receiver - 02200114201  Hydro mechanical cabinet - 02085014101  Runner control mechanism - 02083614101 Installation of feed back System (i) Check that all items are available and are in sound condition. for 24 hrs. (v) All bearings be lubricated and wire rope greased before use. (vi) Kinks and broken stands in wire rope greased before use. . called in drg.with precision level. to avoid any back lash) (viii) Sharp bends of wire rope to be avoided. etc. (vii) Wire rope after installation should be in tension (not loose. : Feedback mechanism – 0208-48-14201 METERING AND INSTRUMENTS AND SHEAR PIN CONTACTS A) METERING INSTRUMENTS i) Calibrate pr. . As such. Wire rope joint to be made as suggested in technical requirement of (iii) the drawing.

clamping and connecting of cables with guide apparatus open. Note : 1. v) Install pressure gauges on draft tube cone.ii) Install metering instrument panel and assemble all instruments as per layout drawing. 2. iv) Complete sealing of glands to ensure water tightness. The limit switches are connected in series with normally closed contact.  Installation of metering instruments – 12100314201 . Ensure calibration of all metering instruments prior to putting them in service. B) SHEAR PIN CONTACTS i) Shear pin is a weak link between strap and guide vane lever and fails in the event of blocking or jamming of guide vanes. penstock. iv) Install all pipes and clamping arrangements with supports. welding of pipes and install supports. spiral case and other instruments as per layout drawing. Carry out hydraulic testing of pipelines wherever called for. With the failure of shear pin guide vane becomes free of its turning movement and strap alone moves and opens the contacts of the limit switch to initiate a warning signal of shear pin failure at UCB. iii) Carryout laying. strikers and clamps as per layout details. iii) Dismantle pipes. Carryout laying. complete cleaning by blowing air at 5-7 Kg atm. providing a little additional allowances in the cable for flexibility. clamping etc. C) ERECTION i) Install all base plates of unit switches. ii) Assemble limit switches and strikers with their respective base plates such that the limit switch remains pressed with striker and the contacts are closed.

Mount the Pr. Pr. Guide apparatus METERING AND INSTRUMENT PANEL 1.: Drg. RCM. . Calibrate DTT'S and RTDS 3. Receiver. PP Set. AUXILIARIES 1 Cooling water system 2 Compressed air system 3 Drainage & Dewatering system 4 Pipes in Turbine Pit 5 Turbine gauge panel piping 6 Turbine pit platform 7 Monorail in Turbines Pit 8 Arrangement of top Cover Drain pipes 9 Turbine rating Plates Note: For erection of all the above Equipment refer the respective drawing & documents of the equipment. Calibration of ammeter. 2. Ref. Voltmeter. Wiring of the equipment to be done as per the scheme. Check and connect the pipe lines as per the technical requirement given in the drawing and document supplied separately by BHEL Bhopal. DTT'S and RTDS as per the scheme. Wattmeter to be done. Gauges. HMC. No. 6. Calibrate the Pressure Gauge. 4. 5.

No Drg. No. Sheets T1 STATION LAYOUT 0-200-00-14201 03 03 T2 INSTALLATION OF PIER NOSE 0-201-03-14201 01 LINER 01 T3 PIPING & EMBEDMENTS IN 1ST 0-201-04-14201 01 STAGE 02 T4 INSTALLATION OF D. CONE 0-201-01-14201 02 01 T10 EMBEDMENTS & PIPES IN SECOND STAGE 0-202-08-14201 02 03 T11 DETAILS OF PIERS 0-202-08-14203 00 01 T12 DRAINAGE & DEWATERING SYSTEM 0-211-01-14201 00 01 T13 DETAILS OF PIERS 0-202-09-14201 01 02 T14 STAY RING HALVES 02-02-01-14201 00 02 T15 STAY RING INSTALLATION 0-202-01-14201 01 02 T16 SPIRAL CASING 0-202-02-14202 00 03 T17 PARTITION PLATES 1-202-02-14201 00 01 T18 Installation of spiral casing 0-202-02-14201 02 03 T19 Arrangement of spiral testing 0-202-52-14201 01 01 CHECK . Rev. T. of Remarks No. No. LINER 0-201-02-14201 01 02 T5 DRAFT TUBE WATER PATH 1-201-00-65602 01 01 T6 EXTENDED DRAFT TUBE LINER BEYOND PIER NOSE KPCL/ADPH/DT L/55-01 02 T7 EXTENDED PORTION DT KPCL/ADPH/DT LINER (5 X 55 MW) SUPPORT L/15-04 STRUCTURE ARRANGEMENT 01 T8 EMBEDDED TUBES FOR FIELD EFFICIENCY TEST 0-201-11-14201 02 01 T9 INSTALLATION OF D. Title Drg.T.ALMATTI HEP TURBINE DRAWINGS – 55 MW UP DATED AS ON – 14/06/2004 Sl.

H 0-203-02-14201 01 02 T 34 G.P. V. SERVOMOTOR R.T20 INSTALLATION OF INLET PIPE 0-202-04-14201 01 TO SPIRAL CASING 01 T21 RUNNER ENVELOPE INSTALLATION 0-202-06-14201 00 02 T22 INSTALLATION OF PIT LINER 0-202-07-14201 01 02 T23 TOOLS TACKLES & ERECTION 0-203-51-14201 02 DEVICES OF GUIDE APPARATUS 02 T24 ARRANGEMENT OF RUNNER 0-201-51-14201 01 INSPECTION PLATFORM 01 T25 MONORIAL IN TURBINE PIT 0-210-09-14201 00 01 T26 GUIDE APPARATUS 0-203-01-14201 01 01 T27 TOOLS TACKLES AND ERECTION DEVICES FOR RUNNER AND SHAFT 0-204-51-14201 00 03 T28 RUNNER ASSEMBLY 0-204-07-14201 01 03 T29 SHAFT ARRANGEMENT 0-205-01-14201 00 01 T30 ARRANGEMENTS OF OIL TUBES OF RUNNER SERVOMOTOR 0-205-03-14201 00 02 T31 TESTING DEVICES FOR RUNNER & SHAFT 0-204-52-14201 00 01 T32 INSTALLATION OF G. V. SERVOMOTOR 0-203-11-14201 00 01 T33 G. V.H 0-203-03-14201 01 02 T35 ARRANGEMENT OF P. SERVOMOTOR L. SET 0-221-01-14201 02 01 T36 ARRANGEMENT OF PRESSURE RECEIVER 0-220-01-14201 03 01 T37 HYDRO MECHANICAL CABINET 0-208-50-14101 00 01 Check .

T38 RUNNER CONTROL 0-208-36-14101 00 02 MECHANISM T39 OIL PIPE LINES 0-210-18-14201 00 03 T40 FEED BACK MECHANISM 0-208-48-14201 00 02 T41 COOLING WATER SYSTEM 0-299-20-14201 00 03 T42 250NB RUNNER AERATION VALVE T43 PIPE IN TURBINE PIT 0-210-17-14201 00 02 T44 INSTALLATION OF FLOWMETER EQUIPMENTS AND ITS PIPING 1-210-16-14201 00 01 T44 OIL HEADER 0-205-02-14201 00 02 T46 INSTALLATION OF METER ING 1-210-03-14201 01 EQUIPMENTS 01 T47 ARRANGEMENT OF GUIDE BEARING 02 T48 ARRGT OF SHAFT SEALING T49 INSTALLATION OF RAILING AND PLATFORM IN TURBINE PIT 0-210-11-14201 01 02 T50 TOOLS TACKLES AND ERECTION DEVICES WITH INSTALLATION OF SPANNER BOARD 0-210-51-14201 00 01 NA 0-206-01-14201 00 NA .

ANNEXURE LOG SHEETS Description Log Sheet No Installation of Draft Tube knee Liner L-01 Installation Of Stay Ring L-02 Installation of Stay ring & Spiral Casing L-03 Installation of runner chamber L-04 Test Certificate for Kaplan Runner Assembly L-05 Elongation of Fitted Bolts between Runner & Shafts L-06 Clearance between Runner and Shaft L-07 Clearance of Guide Vane L-08 Clearance of Guide Vane L-09 Opening of Guide Apparatus depending upon the run of G. Clarence of Guide Bearing L-11 Elongation of Fitted Bolts between Turbine Shaft & Generation Shaft L-12 Centering of Unit axis L-13 Runner Blade Opening v/s Guide Apparatus opening L-14 Observation of measurements during Spinning & Loading (2 sheets) L-15 Page No. . Servomotor Piston L-10.A.