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Erection and Site Inspection Proceedure

1. SEQUENCE OF ERECTION FOR TURBINE-GENERATOR AND ACCESSORIES:
A.

Establishment of C/L & Bench mark.

B.

Pier nose Liner

C.

D.T. Elbow Liner.

D.

D.T. Cone

E.

1st stage Foundation, embedment & pipes

F.

Stay ring

G.

Spiral Casing.

H.

Welding & Radiography

I.

Test Cylinder & Cone

J.

Pressure Testing & Dismantling Test Cone & Cylinder Runner envelop & Matching Piece.
(Make up piece)

K.

Concreting

L.

Second stage foundation, embedment & pipes, pit liner assembly.

M.

Barrel concreting, foundation pipes.

N.

Rotor assembly & Stator assembly in E.B.

O.

Runner assembly runner & shaft assembly pr. test. Trial assembly of G.V with pivoting &
outer Top Cover.

R.

Lowering of Runner & Shaft assembly with Inner top cover final assy, of Guide apparatus.

S.

Auxiliaries & Governor piping

T.

Governor oil piping, G.V. Servo, piping & other Auxiliaries.

U.

Feed back Mechanism.

V.

Lower Bkt. Foundation stools, stator foundation stools

W.

Lower bkt. assembly & lowering, Centralizing.

X.

Stator lowering, Centering, Air cooler assembly, piping.

Y.

Spring assembly. Thrust pad assembly, H.S. Lubrication.

Z.

Lowering of shaft after, fixing servo tube.

STORAGE AND HANDLING INSTRUCTIONS
1. GENERAL
1.1.1

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.

1.1.2

1.2
1.2.1

The following publications by British Standard Institute will be most helpful.
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 should preferably make an angle not more than 30 deg. to the vertical,
and in no case more than 45 deg., while lifting the packing.

1.2.5

Lifting should be done without jerks and impacts.

1.2.6

While handling the packing, the warnings indicated by markings and inscriptions on the

packing boxes such as "HANDLE WITH CARE". "THIS SIDE TOP" "NOT TO PUT LOAD
ON THE TOP", "SLING HERE" etc. shall be strictly observed.
1.2.7

On receipt of the equipment check them with the shipping list. Any omission and damages
should be reported back to SUPPLIER immediately. This checking should be preferably
done in the presence of SUPPLIER's representative posted at site. 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.

1.2.8

Protective coating applied on machined surfaces should not be disturbed. The plastic
covering should be put back carefully after inspection of the component. Some packing
cases may contain VCI (Volatile Corrosion Inhibitor) coated paper, which lets off the
vapour that prevents corrosion of the parts inside the packing case. This should not be
thrown away as long at it is effective. Absence of odour from the paper indicates loss of
effectiveness. Silica Gel and such other chemicals kept in the box as desiccants and
indicators should also be left in the box. The case should be restored to its original state
as -far as possible.

1.3 STORAGE The equipment should be accommodated in permanent place of storage within a week after arrival at destination. It is recommended that either a touch up work is done or complete new film of TRP is applied. 1.1 The warehouse or the covered area where the equipment is to be stored should be clean.4.components are recommend recommended to be stored on shelves.3 It is recommended that films are replaced twice a year.3. 1.2 The cases should be arranged in neat stacks away from walls and at least 100 mm above floor level preferably on rail sections.3.4. The machined surfaces however are treated with corrosion protective chemicals.3.3 To prevent distortion the heavy part and other large assemblies should be kept on even platform.5. Adequate gangways are to be left for inspection and cleaning.1 Guide pads supplied by SUPPLIER have thin lining (2 to 3 mm) of tin base babbit metal chemically bonded to a steel backing. in addition to this.000 kg may be piled up to a height of 2. Sometimes. As these chemicals are to be removed before assembly.000 kg and above should be arranged in a single tier. they are necessarily of temporary nature and can be easily removed.2 As soon as the components are received at side they should be examined for rupture of preventive (TRP) film given at works.5. aluminum foils or plywood is used to protect against mechanical damage.5. Small and medium size.5 meters. preferably before and after prolonged rainy periods. SUPPLIER do not recommend their use .1.1 All these items are generally fabricated from mild steel shot blasted and painted.5 FABRICATED COMPONENTS 1. 1 . The pads are polished to high surface finish. 1. These pads should be stored in such a way as to prevent abrasion. dry and well ventilated. The articles weighing 10. Parts weighting up to 5. and also so far as possible in the sequence of requirement of the parts for erection. These pads must not be stacked one over another. 1. Oil and grease do not protect surface adequately. upright position indication etc. on the side exposed for inspection.2 The babbit metal is quite soft and can be easily scored by ferrous material.4 GUIDE PADS 1. scoring etc. It must have been pretreated with pesticides insecticides against growth of fungus and other micro-organism. 1. It is also recommended to repaint weight. 1.

This can be removed with white spirit. These cases should be fully opened and inspected for any damage on arrival. accidental impacts etc. 2. Small bore pipes are plugged and large bore pipes are covered with flanges. The instruments should be repacked giving adequate cushioning.6 PIPE WORK Before the pipes and pipe works are sent to site. which can be removed with white . it runs the risk of getting wiped off accidentally and exposing that area to corrosion.2 Non -Drying Type (Pigmented) BP 55191 This can be applied with brush resulting in soft non-drying film. a) Non-drying Type (Pigmented) BP 55191 b) Drying Type (Pigmented) AA 55155 c) Drying Type (Black) AA 55154 2. 1.3 Drying Type (Pigmented) AA 55155 This can be applied with brush resulting in thin dry film. The repair and replacement of instruments takes a long time. following guidelines should be kept in mind.1.as rust preventives. 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 SUPPLIER Bhopal would have been given protection against rust by application of one of the following points. but on properly cushioned bases and with adequate protection against falling objects. The instruments could also be stored individually without the packing cases.1 Materials 2. Because on non-drying nature of the film. 1. It is recommended that all the instruments are checked for calibration.1. relays. Hence more care is required during storage.7 INSTRUMENTS Packing cases containing instruments. 2. For site use SUPPLIER recommends the following Temporary Rust Preventives (TRP).. 2. All instruments should be stored in a vibration free area. This provides protection for a period not exceeding 4 to 6 months. etc. Jerks and impacts should be avoided in handling these. are marked 'fragile'.1. the pipes are pickled and coated with rust preventive coatings.1. motors.

shaft flanges.8 microns) such as thrust face. Oil Retaining Sleeve. 3. 3. 2. 4. Vapour Seal Assy. In case the surface is still not clean. 2. moisture etc. B.2 Other materials which would be required in the process are: a) Xylol b) Toluol c) Mineral Turpentine (White Spirit) d) Derusting Solution (Rust Removal) BP 55193 3. 4. A. Allow the solvent to evaporate.3 Dry the surface with the help of hot air blower.1 Remove the old TRP with the help of white spirit.spirit Xylol or Toluol..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. grease. The surface is now ready for TRP application. It may be emphasized that the effectiveness of the TRP is reduced or even nullified if the surface is left contaminated.2 Remove the rust spots using sufficient quantity of derust solution rubbing with clean cloth. 0 SURFACE CLEANING Before any TRP is applied on any metal surface the surface should be free from old TRP. 4. It would provide protection for a period not exceeding six months.2 Category 'B' Large fabricated items having machined surfaces such as Guide Bearing Support Ring.4 Wipe off the surface with clean cloth having small quantity of uncontaminated white spirit. mating surfaces.1. bearing surfaces of Shafts. highly finished surfaces (better than 0. 3. It would provide protection for a period of 12 months.0 TRP APPLICATION The application has been classified into four categories viz.1 Category ‘A’ Journal faces. . It is good for outdoor applications. Finally remove the residual acid from the surface with the help of wet cotton otherwise it may cause further Corrosion. Clean the surface with cloth soaked in water. 3. rust. repeat the process. C&D keeping in view the status of finish and extent of protection desired.

0 TRP SYSTEM OF APPLICATION 5.3. deposition of dust particles by providing an umbrella of polythene sheet.3 Apply second coat of TRP AA 55154 and allow it to air dry. 6.3 During the drying period. 6. 5. 5. shall be given a liberal coat of BP 55191 TRP on threaded and non-threaded portion.2 Apply second coat of TRP AA 55154 on non-threaded portion. having no other protective film such as plating.2.3. galvanizing etc.2 Container and brush must be cleaned after application with white spirit before keeping for next operation. The surface coming in contact with the job should be given a . Allow if to air dry for 12 hours. 5. such as Aluminum sheet.1.1. plywood etc.0 PRECAUTIONS 6. 5.3 Jobs classified.1. after cleaning.4. 6.1 Jobs classified in Category 'A' and ‘B' will have 3-coat system as detailed below.3 Category 'C' All fasteners and threaded portions excepting in such cases where the job has already a protective film each as plating. 5.1 After cleaning.2 Jobs classified as Category 'C' will have 2-coat system as detailed below. 5. should be replaced after application of the TRP. 4.2 Apply second coat of AA 55154 liberally and allow it to air dry.1 TRP should be stirred well in the original container so as to make a homogeneous mixture of its constituents. 5.3 Fasteners of small size.2 Clean dust from the surface and apply a coat of TRP AA 55154 and allow it to air dry for about 12 hours.2.2.1 After cleaning apply one coat of AA 55155 and allow it to air dry for 12 hours. apply one coat of TRP AA 55155 and allow it to air dry for 12 hours inside the store. as Category ‘D’ will have two-coat system of TRP as detailed below.1 After cleaning apply one coat of AA 55154 on non-threaded portion and a liberal coat of BP 55191 on threaded portion. galvanizing etc. given for TRP film. 5.4 Category 'D' Small machined components & other components not defined above. 5. the wet film should be protected from. 5. 5. 6.4 Protections.

6.liberal coat of AA 55154. corrosion spots etc. . the surface of TRP coated jobs shall be examined for any damage. 6.5 Normally after an interval of six months. the repair should be done and TRP System applied.6 All materials specified above can be ordered on SUPPLIER.

2. 3. In case of . surrounded by ribs. 4. UNPACKING AND CHECKING OF PLANT EQUIPMENT 4.1 All measurements shall be taken as per the checklists / log sheets of field quality assurance and recorded. 3. 2. MEASUREMENT AND RECORDS 3.1 All materials shall be unpacked and checked well in advance of erection work.2 For good bonding. vibrator must not touch any embedded or machine parts. efforts shall be made to achieve best possible results. old concrete surface should be made rough and if required should be chipped. 2. 2.4 Even though erection tolerances are given. 2.1 Concreting does not come under SUPPLIER scope of work.3 Final log sheets shall be prepared at each stage of erection work and signed by representatives of SUPPLIER and customer. Grouting pressure should not be more than specified at relevant places.2 For spiral casing with stay ring.GENERAL GUIDELINES FOR ASSEMBLY AND ERECTION 1.8 Grouting wherever required shall be done from bottom upwards as slowly as possible. In case of any deviation corrective action shall be taken. 3. POWER HOUSE AXIS Customer shall provide axis of powerhouse and elevation. 2.6 Recommended setting time is allowed before taking up further works. customer should ensure that following precautions are taken prior to and during concreting.5 Concrete foundations.7 During concreting. 3. pedestal of equipments are to be chipped and made even to achieve surface contact for better load transfer to foundation.4 Concreting shall be done in steps / lifts. However.3 All surfaces should be cleaned and washed with air water jet. Established centerline and datum shall be made available on steel plates embedded in concrete nearest to respective unit in powerhouse. measurement shall be taken before and after concreting. 2. 2. CONCRETING AND GROUTING 2. Grouting shall be stopped when grout material flows out from other grouting holes provided for each space.

surfaces must be free from foreign materials such as grease.9 Before starting seal welding on the other side. 5. oil. 5. WELDING 5.1 Mark zone of approximately 300 to 400 mm length as shown.8. Cup seals.6 Proper root gap is maintained for welding to avoid undercut. gouging / or grinding is done and dye penetrant is carried out.2 Recommended electrodes are used wherever specified.2 All rubber products eg. . are preserved till their use.10All site weld joints of stayring and spiral casing are radiographed or UT done as per . in chalk powder / water container with water replacement every week / water soaked saw dust. These shall be removed before starting seal welding from other side. for a distance of at least 20 mm from weld joint on either side. 1 is followed for making root run.4 Surfaces are cleaned thoroughly before starting welding. 5. welding as per sketch no. 5.5 Electrodes are suitably baked in oven prior to their use to 300 C at least for two hours / as per manufacturers guidelines. 5.1 Welding is carried out by a qualified welder.8 Wherever circumferential welding is involved. suitable action in line with QAM/SP shall be initiated to inform concerned agencies.any damage / shortage.3 Edge preparation is checked / prepared wherever required as per drawing.3 After this. Storage and preservation of materials shall be ensured as per manufacturer instructions. abrupt ridges and valleys. 5. 5. welding may done starting from two or four points and proceed continuously. 5. 5. 2 may be followed to minimize deformation of equipments.8. If the gap is more than 5 mm packing strips are provided to minimize shrinking and welding deformation. 5. O-rings etc.8.2 Complete welding in various zones starting simultaneously in opposite quadrants. Preheating / post-heating of surfaces / stress relieving of weld joints is carried out wherever necessary as per technical requirements.7 After root run completion of welding dye penetrant testing is carried out and corrective action taken. 4. paints etc. over laps. . In other joints skip / step welding as shown in sketch no. 5.

edge preparation and welding is carried as per drawing requirements.12In case welding is provided in pipe works.technical requirements of concerned drawing.11 After completion of site welding and grinding painting of effected areas is to be done. 5. 5. .

a thin coat of white lead / hold-tite may be applied. TIGHTENING OF FASTENERS 8. be sure to proceed symmetrically and uniform.4 Clean the ends and make joint with suitable adhesive. 8. The tightening wherever specified should be followed. If not. Anabond. etc.1 Area of each groove equipments is measured / calculated. 8.1 During assembly of close fitting parts.2 While tightening the fasteners.e. RUBBER CORD SCARF / STRAIGHT JOINTING 6. 7.2 On the other joints of sealing surfaces. eg. molybendenum disulphide or graphite grease in order to prevent scratching or seizing at the time of tightening or loosening.3 All thread portions and fasteners are proved in advance for checking healthier threads. In general it is recommended to keep the length of cord 1% less than the actual requirement. USE OF LUBRICANTS 7.3 Prepare by cutting or / and grinding as shown in sketch no. 6. 6. moving or sliding parts. . 6. it is recommended to apply a thin coating of anti seizing compound i. Rubber cord of 80% to 90% of the groove area is selected.6. After fully tightening the fasteners these should be locked as called in the drawing. 3. so that there is no unbalanced tightening in the joint.2 Cut the cord as per length required including scarf / straight joint. 7. rectified suitably for obtaining smooth threads. Elfy. 8. a thin coat of grease is applied.1 On the threads of heavy duty fasteners.

9. 10. Welding & Cutting . 9. 10. B. 9. 11.10Blow compressed air to oil and grease ports. instruments required for erection.5 Check for PO number. check all items of the concerned drawing are available. load grease ports with grease and plug them temporarily. CONFIRMATION BEFORE STARTING ERECTION / ASSEMBLY WORK 10. 9. 10.4 Check for all test results of shop wherever necessary. ASSEMBLY OF EQUIPMENTS 9.1 Before taking up any assembly.8 Check for shop dowels. 9. 9.1Confirm availability of all tools and tackles required for erection works. if any and ensure its availability. 10.2Confirm availability of reference drawings and technical documentation related to the project. PREPARATION OF FOUNDATION BLOCK OUTS 11. 9. Check for any damaged components and rectify if possible after obtaining concurrence from concerned manufacturing unit. assembly match mark and axis marking for each assembly.1 Check the foundation block outs dimension and locations. if necessary carry out chipping of foundations to required dimension and elevation.6 Ensure that individual components are cleaned & are free from burrs and scratches.5Ensure installation of generator assemblies with reference to Radial line of assembly. 10.4Confirm availability of all connected equipment’s.3Confirm customers certified centre line and established datum available on embedded plates on the concrete nearest to the pit. 9.9 Temporary plugs / protections provided should be retained till final assembly.9. 9.3 Check for all concessions /deviations raised at shop if any to be taken care at site and ensure compliance.7 Check for special lifting arrangements of assembly / sub assembly.2 Check for all technical requirements of drawings to be satisfied at site and ensure their compliance.

Use rubber hoses correctly as per coding. 10. 4. Periodic testing of 'D' shackles. 5. hot welding slag arc flashes etc. 6. 5. plan your activity well in advance. gearbox to be done. For this. . 4. hose valves Regulators etc. turn buckles. Never stand under heavy loads. be lying in the area where cutting or welding is being done. sand etc. 2. Lifting of loads shall be started slowly and erratic movements avoided. Ensure against leakage of gas from torch. Do not subject wire rope beyond safe working loads. Use proper protective clothings. 4. Welding area should be properly ventilated to minimize air pollution in the surrounding area. Periodical checking of pressure gauges of regulator to be done. 3. 8. Periodic greasing of ropes should be done to avoid rusting and decrease friction. Oxygen green or Black house. (D) Cranes 1. Grease the wire ropes regularly. Use proper pipe clips. (c) Lifting Tackles 1. Fire extinguishers. While giving signals to crane operator standard signals with which operator is conversant be given by one man. 7. 9. Never look at welding arc without using welding dark glass. 5. should be available nearby. Store gas cylinders away from "Sources of Heat" Over Furnace. Periodic checking of electrical controls and brakes. Do not keep the load suspended for more time than absolutely required. Pull lifts and chain pulley blocks be done. 6. 3. 11. Oils Dyes Acids Enamel paints and Varnishes etc. direct sun rays. 2. Ensure proper earthing of work & welding machine to avoid electric shock. Periodic inspection of ropes and safe load testing be done. welding glass to avoid burn injuries due to welding spatters.1. Store gas cylinder in well-ventilated place. Acetylene Red hose. Store ropes properly to avoid kinks. 3. 6. Avoid wire ropes coming in contact with sharp edges while lifting. 2. No flammable material like Petrol.

(a) Draft tube drain pipe. F. Embedded Parts Embedded Pipe in First Stage (A) Pre-Erection Checks. 4. (ii) Check that all the necessary tools. drilling machines) 1. Acids and Alkalies 1. 8. 7. 4. 3. Always add Acid to water. Use acid proof rubber gloves. wash off as quickly as possible with a large quantity of clear water and then rush to doctor. (i) (iii) Pipes to be erected. whiie in motion. Avoid standing in -front of the wheel or cutting tool. Use proper protective clothing. Do not apply excessive pressure on cutting tools to quicken the process. Tool/Grinding wheels be secured properly. 6. 3. Crane should be regularly maintained as per its maintenance schedule. equipment & material required are available at site. Whenever there is any acid or alkali burn. Guards above moving parts should be in position.7. . (B) Erection. Never handle any acid or alkali with bare hands and without protection to eyes. (i) Check for availability of all the items as per relevant drgs & bill of material and clean them. aprons. Never add water to Acid for making dilute solution. Use safety appliances like goggles hand gloves. 5. Ensure electric hand tools are free from electric shock. 2. (b) Spiral drain pipe. rubber aprons and goggles as per Job requirements. gum boots. (E) Rotating Small Hand Tools (Like Grinding. Position above pipes as per drawing dimensions & elevations. Correct speed be ensured of rotating wheels. 2.

Erect bend pipes and position support. Pressure test pipes as per values given in drawing. (v) Ensure proper clamping of pipes so that they remain in the same position during concreting. 9. Blank the open ends of the pipes with M. Field efficiency and discharge measurements are to be made for all units as per drg. 3. Mark Bosses on penstock DT liner / spiral casing and weld suitably. 4. Bends of St. Clamp supports and put covers. Field efficiency test for pipes 1. 7. 2. Hand over for concreting. Tack weld at minimum 4 points to lock. Embedded pipes for field efficiency test . Obtain datum line of penstock. (vi) Hydraulically Test the pipes as per Drawing. After concreting check pipes for any blockage concreting.(iv) Weld the pipes as per details given in drawing. Steel pipes to be made at Site. 8. 5.S plates. 6.

2. Tolerance: (a) Vertically 1 . Match marks etc. Final checking of alignment and verticality. 7. Bolts and Turn buckles lock. Lower two top segments of cone and align. matching and then clear for full weld. 7. Lower Pier nose assembly using winches wire ropes or suitable crane then check level and elevation. Transport D. Flush grind final run. top. Erection of Draft Tube Cone : 1.r. left side. Arrange all bottom. 11.t. Hand over for concreting. Hand over for concreting. align. erect drain box assembly & connect DT drain pipe & weld. Lower two bottom cone segments. Knee liner segments in Sequence. Draft Tube Elbow Liner 1.mm/metre. 2. Dye tests the root run. right side segments and assemble them complying with elevation w. Use shims / packing plate for achieving required elevation. H. Check Unit Nos. Fixing of Anchors. 5. 2. (b) Elevation within ± 2 mm. Stich welds assembly. 3. 6. Fix foundation bolts and tighten. 4.Pier Nose 1. Weld as per relevant Standards 9. Lower bottom most . Check level of pedestal/ Steel supports. 10. tighten. 4. . 5. relevant drgs. Check center-to-center distance and align. 6. 3.T.segments and match. 8. align with DT liner and Tack weld.D. Check dimension elevation.

5.t. If it is not as per drg.r. Measure the inner diameter of cone at the top. Top center of D.T. If all readings are ok.T. then tack weld all turn-buckles. Weld the joints as per relevant standards and dye test the root run. liner center within ± 2 mm. 7. 4.3. Correct if necessary. Check elevation of DT cone as per drg. Release for concreting up to casing of piers for spiral casing and stay ring. . 6. 8. X & Y axis within 2 mm. correct it. Check alignment of cone w. cone to be in line with D.

(iii) Use the sling given as per drawing and lift. (vi) Check welds preparations for site welding joints as per drawing. Align center & level with respect to station.05mm feeler gauge should not go. STAY RING 29 2. y Axis) & Datum elevation given by the civil wing. so that stay ring pedestal are resting on the stool.NO DESCRIPTION PAGE NO Erection of Foundation Parts 1. (v) Ensure Tightness of joints 0. PIT LINER 31 32 STAY RING (A) PRE ERECTION CHECKS (i) Check for availability of all the items as per drawing. . Center Line.SL. (iv) Lower the Stay ring on stools. (vi) No step at joints on top & bottom machined surfaced after joining. (ii) Check for any damage during transportation & repair if necessary. SPIRAL CASING 30 3. Check radius at top & bottom machined bores. (viii) Seal welding of Joints to be done as per drawing requirement. (B) ERECTION (i) Transport of stay ring. (ii) Assemble in service bay and heat and tighten the Joint bolts to achieve elongation as per drawing. (iv) Check & prove threads on joint bolts & nuts. (vii) Check locking of Joint bolts & Nuts. (iii) Check all the pier details as per drawing. RUNNER ENVELOP 4. using hydraulic Jacks/Mechanical Jacking screws. Conduct NDT tests as per drawing requirement. (v) Establish center line (x.

(x) After successful completion of Hyd. (vii) Lower the test cylinder and fix it in position. complete the sealing run. (vi) Radiograph and ultrasonic Test for all butt Joints to be carried out as per drawing requirement. Test. Pre Erection Checks. (xi) Complete the installation of holding down bolts.SPIRAL CASING (A) PRE-ERECTION CHECKS. (xiii) Carry out erection. anchors. (v) Back gouge.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). wedges. & lock all the hardware. (ix) Carry out the Hydraulic testing of spiral casing at pre test pressure and time as given in drawing. bolts & jacking bolts & other hardware. remove test cone & test cylinder. (iii) Check and prove threads on holding down. (xiv) Recheck the alignment leveling of stay ring before handing over for concreting Runner Envelopes A. . (iv) Check weld preparation for site welding joint as per drawing. (iv) Dye check the weld seams for any surface defects in the plate. (ii) Check for any damage during transportation & repairs if necessary. (iii) Weld the spiral segments as per technical requirements given in the drawing. grind & dye check for seal run. (i) Check for availability of all the items as per drawing. (xii) Check the leveling & stay ring. (viii) Place test cone and weld with spiral inlet. welding and NDT of inlet pipe as per drawing. (B) ERECTION (i) Assemble the spiral segments as per drawing & ensure that gap at joints in axial or radial direction is 2 to 5m.

2. vi. testing & Testing of Cone assembly 2. axis of stay ring and check diameter. Welding to requirements as per drawing. Erection. Welding of anchor plates. 4. 1 mm. Runner & shaft assembly with outer top cover PAGE NO. LOWER THE PIT LINER SEGMENTS 1. cone & Runner envelope. t . T. Trial assembly of G. anchoring and welding with stay ring. iv. water and other pipe lines. . after lowering for Ist out before stay ring. Fastening. ii. The mechanical surfaces for fixing the servo motors are equidistant from X & Y axis (with tolerance as per drawing) & are vertical. Welding of make up piece with D. NO 1.V with outer Top Cover & dismantling 5. Pivot ring assembly 3. 5. DESCRIPTION Runner assembly in Erection Bay. SL. vii. Outer Top Cover assembly 4. Check diameter. Ensure placement of sufficient sleeves for routing cables etc also. Spider assembly to be carried out before concreting. Guide Apparatus Assembly 6. r . as per requirement of drawing. v. i. Top dia of pit liner (± 5 mm) 3. Trial Assemble two halves at service Bay. Recheck: the centering of Runner envelope after concreting. Runner Envelope to be lowered. B. Centering w . iii. PIT LINER ERECTION A. Also check that embedded pipe carrying in this state of concreting are installed and the free ends are blanked off by welding metal plate. per meter 2. Installation of pipes / Pipes sleeves for routing of air.1. Dye testing of seal welding of joint flange to be done.

3. Oil-Header 13. 5. During reassembly of runner as per drawing. Guide Bearing 11. sliding blocks and other components against any scratch. b) Check the machined surfaces of piston. d) Check that the threaded holes and fasteners are not damaged. Installation of Metering Instruments RUNNER ASSEMBLY 1. f) Check correct joining and assembly of rubber cords and other seals. sealing. cup scales etc are in good condition. i) Check that the pre stressing of fasteners is done as per drawing reference. Lowering of runner assembly with inner top cover &final assembly & centering 8. h) Check that the locking of Bronze Bushes are as per drawing. 2. Installation of Regulating Ring 9. Check the match markings during dismantling (if the runner is received at site in assembled condition). washers.7. plugs and valves are as per technical requirements/details of drawing. c) Check that the rubber items such as 'O' seals. Perform visual inspection for any damages. report to unit if any abnormality is noticed. e) Check the grooves and rubber cords for their sizes. Shaft seal 12. 4. Perform overhauling internal checking of runner as per drawings. g) Check the free movement of sliding blocks. check the following: a) Ensure usage of proper / suitable settings for lifting & twining of runner. servo motor cylinder. dents etc. Governing Equipment 14. of G V. Installation. . Check availability of all materials as per drawings. j) Check that the locking on laterships. servomotor 10.

Drawing to be referred 1.k) Assemble runner shaft and servo tube with runner as per drawing l) Elongate coupling bolts as per the values mentioned in the drg. Arrangement of all tubes of runner servomotor 5. m) Measure and record the clearance between runner hubs & blade. Shaft arrangement 4. n) Perform testing of the Runner as per test procedure technical data provided in the drawings supplied by manufacturing unit. Tools tackless for runner shaft 2. Testing devices for runner & shaft . Runner assembly 3. it should be as per drawing value.

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

Instructions for bedding of pads) before runner shaft assy start. 3. 7. Carry out testing of runner in the manner stipulated in drawing and check leakages through sliding mechanisms. D. with shaft in horizontal position (Ref. HP compressors and commission them / alternately install these equipment’s provisionally for testing of runner. 11. 4. Maintaining accessibility with shaft suspended. 6. Carry out laying and connection of pipes as per the scheme of testing supplied by the manufacturer.5. Check soundness of runner shaft assembly joint with the help of 0. Carry out cleaning. Prepare FQA log sheet for elongation tightening & completion of runner shaft assy. After successful testing. If possible. through the cup seals of runner blades. Install PP set. 12. HYDRAULIC TESTING OF RUNNER & CHECKING LEAKAGES 1. 9. 10. 5. Transfer and lower the shaft on to runner. Note : Oil leakage is not permitted. through the cup seals of runner blades. feeler gauge will not pass. coinciding the match marks.03 feeler gauge. Note : Oil leakage is not permitted. 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). In the event of correct assembly. Cover the open end of servo tube temporarily to avoid entry of foreign materials in to the system. Install O-seal. 2. neutralization and oil rinsing interiors of oil servo tubes. Carry out locking of fasteners and dowels as called for. Insert the lower part of servo tube in shaft bore before runner shaft assy start. tighten to required stress / elongation as per technical requirement & lock the nut. pressure vessel. Testing be continued for the duration as indicated in drawing. . lower and assemble servo tube with piston rod coinciding match marks and using dowels. 8. lower the shaft and carry out assembly of shaft with runner. Check and prove bedding of guide bearing pads with guide bearing journal of shaft. acid pickling. carry out locking of all fasteners as called in drawing. Install all coupling bolts.

Turbine guide bearing skirt rests over this bracket. Lower runner shaft assembly further to make GB skirt rest over the bracket. INSTALLATION OF RUNNER SHAFT ASSEMBLY 1) Runner shaft assembly is lowered along with turbine top cover. Runner shaft assembly is supported on top cover with a suitable supporting bracket fitted at the seat of turbine guide bearing.E. 2) Lower the complete assembly in to runner chamber and carry out assembly of top cover using seals dowels and fasteners etc. . 3) Carry out leveling at turbine shaft flange and centering of runner with runner chamber.

During final assembly of guide vane also. Final assembly procedure is also given in following pages. 4) Ensure availability of proper tools slings etc. Lock the bolts as per drawing requirement. 10) Lock the bolts as per drawing requirements. Grinding to be done if required to achieve the level. 2. for erection of pivot ring. Clean. . 2) Perform visual inspection for any damages. During lowering of G. 7) Lift the assembled pivot ring. Clean joint flanges and check for smoothness. ASSEMBLY OF OUTER TOP COVER Outer top cover is in 4 segments. The segments are to be lowered in pit as individual segments. bolts and tighten.S. 8) Tighten the holding down bolts. the outer top cover may be lifted as per drawing and position Guide vane assembly.V.  Perform visual inspection report  Ensure availability of T & Ps. Trial assembly to be done by lowering guide vanes using lifting tackles. Check availability as per drg. Put H.D. 5. if any. Report to manufacturing unit if any abnormality is noticed. 5) Check the runner envelop flange level. Assemble all four segments of outer top cover inside turbine pit. and lower them over the cleaned resieng surface.V. 3. Match holes of speed ring flange with that of outer top cover. Sling the assembly and lower on speed ring flange as per match mark & support / hang suitably. 3) Check the matching surfaces of pivot ring for any burr / foreign materials. the G.PIVOT RING INSTALLATION 1) Check for the availability of all the materials as per drawing. 6. are lowered after lifting Top cover in site using hooks provided in barrel. The procedure of Trial assembly is given in following pages. 9) Align & level pivot ring as per instructions given in drawing. for their assembly. 6) Lift the pivot ring individual segments and lower them on wooden pegs kept on the runner envelop / stay ring. 1. 4.

2) Generator barrel is painted except stator. Grind them if necessary to achieve drg. and upper bracket foundations. 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. ERECTION OF GUIDE APPRATUS PRE-ERECTION CHECKS 1) Generator barrel is cleared of all civil materials and chipping of stator. Check the leveling of speed ring top flanges and groove area. Value. 6) All components of guide apparatus and erection devices as per drawing are received. 5) Horizontality of stay-ring flanges checked and corrective action executed wherever required. . lower bracket foundations completed. lower bracket.

4) Assemble lower ring-using dowels to coincide with XY match marks of stay-ring. to check and ensure the clearances of guide vanes with top cover at leading and trailing edges are as per drawing requirements. 7) Lower and position guide vanes as per number match marks. Lift the top cover precisely leveled with the help of turn buckles and crane and lower it on stay-ring. 9) Position the top cover using dowels and reference match marks. 12) Bring all guide vanes to close position. In case of deviation from the drawing requirements. doweling of lower ring and inner top cover & outer top cover. . 11) Check and ensure free turning of all guide vanes. trial clearances and free turning movements of guide vanes are as per technical requirements and to establish. While tightening the nuts of holding down studs till tightening of all nuts of top cover is finally completed. lower ring may be assembled finally with seals. corrective action is taken wherever required. top cover positioning and dowelling. 90 degree apart on top cover. 3) Depending on type of design. 14) Lower inner top cover & align it.TRIAL ASSEMBLY OF GUIDE APPARATUS 1) Even through the guide apparatus assembly is proved in the manufacturer’s unit. 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). 8) Assemble four upper guide vane bush housings. 13) Carry out bedding of guide vanes and correction if need be. lower ring. 2) Remove preservatives and clean all the components of guide apparatus and prepare the components for assembly as per general guidelines. 5) Centre the pivot ring bent runner envelop 6) Install all holding down bolts of lower ring and complete tightening. 15) Complete reaming. FINAL ASSEMBLY OF GUIDE APPARATUS PRE-ASSEMBLY CHECK 1) Dismantle and remove all the components assembled for trial assembly. Note : Thin layer of grease is applied on bearing and guide vane lower stem before installation.

After installation of bush. 4) Lower guide vane in position.r. Note : After final assembly of guide apparatus. 12) Install link mechanism and adjust guide vane end clearances. the retaining ring shall be suitably machined. cm or as indicated in drawing. 6) Assemble guide vane bush houses with seals and check free turning movement of each guide vane. 15) Install connecting rods of servomotors with regulating ring and carry out pre-stressing of guide apparatus mechanism (refer instructions described separately). 13) Check free turning movement of all guides vanes from full close to full open position. Lower labyrinth on lower ring is within the specified limits.check gap between top cover & stay ring flange by 0. 10) Check and ensure centering of runner w. 14) Position regulating ring to close of guides apparatus complete centering and provisional locking. The complete mechanism should turn freely at oil pressure not more than 5 kg/sq. 11) Install regulating ring and servo motors (refer instructions for installation of servo motors of different variants. bedding clearance and clearance between lever and lever stopper / collar. In case of interference. 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.2) Check the rubber cup seals and O-seals do not carry any cracks and are not de-shaped.03 mm/met. 9) To facilitate alignment of generator. its .which should not pass). (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. described separately). 8) Lower runner assembly with inner top cover runner shaft assembly. 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. In case guide apparatus fails to turn at this pressure. 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 . 3) Install cup seals and retaining rings on lower bush bearing of guide vane and ensure that retaining ring does not interfere with lower collar of the guide vane.03 mm feeler gauge .t.1 mm Leveling with 0.

2 Plot the graph from the values obtained check that the curve nearly matches with the design values. when the oil pressure is applied for opening of guide apparatus. governor and completion of working mechanism in all respects. KINEMATICS OF GUIDE APPARATUS 8. 6. according to drawing instructions on servo motor piston for closing and measure the amount of movement of piston. 4. Complete locking of turn buckles with lock nuts. back by same amount i. when measured with 0. check that regulating ring is not disturbed and remains in the closed position of guide apparatus.03 mm feeler gauge. 5. Movement of piston so measured is the tightness required in the guide vanes.1 Upon completing governor adjustment and readiness of starting the machine check relationship of guide vanes v/s servomotor and governor.2 Clearance between adjacent guide vanes all along their height is 00. Apply oil pressure. Release the oil pressure and install the piston of both the servomotors from the end support at a distance of tightness value measured. 7. Governor and guide vanes v/s runner blade. governor for closing is as per design requirement (for Francis turbine). 8. PRE STRESSING OF GUIDE APPARATUS MECHANISM 1. Tighten lock nuts of turn buckles of both the connecting rods. forward by 15 mm by adjusting the length of connecting rod with turnbuckle. 7.3 Guide apparatus servomotor opens to its full stroke. While doing this.e. 16) Prepare FQA log-sheet for completion of guide apparatus assembly in accordance with field quality checks. Apply pressure for closing of guide apparatus and check that. 2. 7. . Tightness in guide vanes is determined in the following manner upon the readiness of oil pressure system. In closed position of guide vanes.1 The stopper of servomotor moves freely in and out. 7.causes must be investigated and removed. 15 mm in the similar way. 8. Take the piston of servomotors without stopper. bring the piston of servomotor with stopper. for opening and closing is as per design requirement (for Francis turbine) Check relationship of guide vanes v/s servomotor. 3.

Keep the piston rods of both servomotors in fully closed position (i. Fasten the cover with stud nut. 5) Assemble the covers using “O” ring. Fasten the covers by tightening the studs and nuts. D. 3. Align both the servomotors to drg. Locking of nuts to be carried out only after satisfactory hydraulic testing. & after checking the opening and closing of servomotor and checking the seals are intact.e.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. Lubricate cylinder surface profusely with turbine oil as soon as piston rings have entered the cylinder remove clamp. 7) Assemble the cylinder cover using cup seals. the same may be over hauled. Check and clean the base plates mounted on pit liner. If necessary clean and dress with triangular smooth file. Lower servomotor stopper in position to lock the movement of piston. 2) Check the cup seal “O” rings of servomotors for any cracks or damage. Push / pull the servomotor piston fully in/out. Check the threads of piston rod. Check the interference of cup seals I. 3) Clean thoroughly all parts and inside surface of piston and cylinder with solvents like diesel / petrol check the surfaces of piston. Level the servomotor precisely (horizontal) check level by precision block level (accuracy 1 . cylinder. 2. For this following procedure may be adopted. 1) Dismantle the servomotor after proper match marking of all components / joints. with sleeve. Check vertically. Couple mounting plates with servomotors using studs & nuts. taking care to keep the slot portion of piston towards oil ports. piston touching the respective cylinders ends). piston rings. used for pressing the piston rings. for any scratches. 6) Insert the piston assembly in the cylinder in vertical position. B) INSTALLATION 1. Lower both the servomotors in their respective position. 4) Use new cup seals and prepare “O” ring if assembled ones are worn out and if replacement is necessary. Dimension. 5. 4. 6. bushes etc.

Assemble the piston rod and connected rod initially. 7.r. 12.02 mm/m) on piston sleeve level should be achieved with 1 division. vi) Apply liquid sealing compound (hold tight at joint faces of the Bearing oil sump. 8. The connecting rods of servomotors to be assembled with regulating ring keeping the guide apparatus fully closed. Thoroughly clean all parts and joint faces of bearing oil sump. tighten the joint faces and check the bedding. ii) Clean the bearing pads with solvent like petrol and white spirit. servo stroke indicator scale. TOLERANCE: 1. Also check and set if necessary the G. Use suitable oils both during above Calibration. Also check the bedding of Disc. A) i) Pre-erection. Center line servomotor is parallel to Y axis and at a distance as specified in the drawing (within 1 mm). V. 2. regulating ring (within 1 mm).t. 11. keep 25 mm gap between piston rod and connecting rod. Bottom ring) B) Erection (before alignment) . otherwise they are to be welded using strip as shown in the drawing no. servo cylinder (Not of piston rods / connecting rods) and level the servomotor.0 GUIDE BEARING. Elevation of servomotor w. If necessary Scrapping can be done. v) Check the working of oil level indicator in Separate oil container out side. 10. Maintain the distance 1985 of G. Filler gauge can be used to find out the gap. If necessary scrap the face. Check their bedding with the bearing journal of the shaft.Div = 0. iii) Measure resistance of RTD with standard mercury Thermometer on heating as well as on cooling Cycle. iv) Check the groove sizes and prepare rubber-sealing Ring.V. Check that stud has spherical curvature where it is pressing the disc. 6. 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. Use engineers blue on one face. Check the guide vane bedding its nut as per drg value correct it with both the servomotor operation. 9.

runner centered with respect to runner envelop and rotating parts are lying vertical and locked. Apply molysuff or any other anti thread seizing grease on the thread of stud. Shaft with in 0. Final boxing up of turbine bearing can be taken up. set the gap of 0. O-seal respectively. Assemble the two halves of bearing housing. 2. 4. bolts nuts washer. Bearing housing should be checked for any leakage.2 mm. . dial indicators at 90° apart to measure/check the shaft movement.2 between the disc and stud (Spherical surface) and lock the nut. 8. Record all the readings achieved in log sheet. Install 2 Nos. Assemble bearing oil level controller with its probe. Re-check the above clearance. Remove the kerosene after testing. Assemble bearing housing with dowel and pins.15 to 0. Set these dial indicators to zero value. Press all the pads so as to touch the shaft journal. C. 1. 9.(i) Fix. Clean the inside area thoroughly with compressed air/Vacuum cleaner and moping cloth. Mount RTD and MST (already calibrated outside). Suitably blank it for testing with kerosene for any leakage through “O” rings. Lower the bearing pads and stud and nut in their respective position (i. DIRECTION (AFTER ALIGNMENT) Note: After the unit axis alignment is completed. with respect to RTD & MST connections).e. 5. (iii) Assemble the pipe assembly in their respective position. (ii) Install the rubber ”o" rings and position the bearing housing matching with unit axis marked on the top cover and bearing housing. studs called in guide apparatus drg. With all bearing pads touching shaft. (v) Cover/protect the bearing from dust/foreign material till alignment is complete.r. Insert disc and bring stud near to disc to avoid falling. Match with axis and complete the assembly of bearing housing. 3. Center the center piece with respect to turbine shaft journal (with runner at centre) Tighten nuts and washer. 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. (iv) Fix studs with holdtite. 6. taking care that no step at any joint. 7.t. Install bearing cover with all other items as per drawing with "O" seal. Gasket etc.

2. 1. 2.4 Install cups and lip-type rubber working seal and join it with suitable adhesive and complete the assembly of cover plate.5 Install upper working seal. place the isolating seal and housing and cut the extra length of seal.6 Carry out drilling. 2.7 Connect cooling and pressure water piping 3.2 Assemble housing of isolating seal.3 Place the cover plate in position and assemble it with housing.3 Check and grind the top surface of cups. reaming. generator shaft and a oil guide / deflector installed on shaft. ERECTION 2. if any projecting over and above the surface of ring supporting the working seal. generator shafts.TURBINE SHAFT SEALING 1. join and assemble cover plate. clean them thoroughly and check the joint faces for flatness and absence of damage. 2.1 Dismantle components of shaft sealing.1 Assemble base plate / housing of isolating seal with top cover along with “O” seal. Note: i) Joints of rubber working seal are made taking into account the direction of rotation of the machine. PRE-ERECTION 1. Oil pressure for opening closing of runner blades is supplied through main slide valve of runner installed in HMC of governor.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. Test the isolating seal by air as per chemical requirements of drawing and confirm expansion of seal under air pressure. . OIL HEADER (REF SKETCH) 3. The leakage from the runner passes to pressure pumping set through the bore of turbine. 2.2 Install and join isolating seal using suitable adhesive such as anabond / elfy. 2. doweling of turbine shaft sealing frame with top cover. maintaining clearances between rotating and stationary parts as called in drawing (use liquid compound / hold tite at the joints of housing). 1. 2. ii)Clearance between rotating and stationary parts is maintained by grinding wherever necessary.

5.The runner feed back system & the indicator showing the position of runner blades are also mounted on the oil header. 5. ERECTION OF OIL TUBES & OIL HEADER Following sequence of activities to be followed for erection of oil tubes and oil header: 5. 5. and in no case it should exceed the value of diametral clearance.7 Lower the assembly of central pipe and pressure box.6 Lower and assemble generator tubular shaft with generator shaft. 4. 5. PRE ASSEMBLY 4. 5.9 The allowable value of throw for central pipe is preferably 75% of the diametral clearance at . Upper flange of oil tube (lower) should be parallel to turbine shaft coupling face.1 Check individual component of oil header is prepared to technical instruction.3 Insert middle tube inside generator shaft in erection bay and then lower in the pit keeping oil tube projected by 200 mm approx. check throw of spigot in generator tubular shaft and horizontality of top flange. 4. 5.3 Place oil header assembly upside down and ensure the movement of pipe line assembly. Oil header is assembled with runner shaft logged after alignment & center of runner.4 After connecting middle tube to lower tube and assembly of generator shaft with turbine shaft. 4. 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.2 Lower the assembly of runner. 5. in the oil header bush is smooth. Check oil deflector items machined surfaces are true and check level and surface finish exciter shaft for trueness (where oil deflector is assembled). 4. check the horizontality of its top flange and throw of spigot. 6 and pressure box is preferably 75% of the diametral clearance at pressure box bearing. check throw of central pipe and pressure box. 5. shaft and inner top cover along with oil tube (lower) in the turbine pit (preferably after testing of runner on erection bay). 5. After assembly with upper tube. check the horizontality of flange of middle tube and throw of its spigot.8 The allowable value of throw for point no. below generator shaft to facilitate coupling of tubes. 5.1 After assembly of runner.4 Check and record the diameters of bush and pipe line assembly. 4.5 Assembly oil tube (upper).

centralize oil bath to get the uniform labyrinth clearances. Lower the assembly of Runner. . 5. OIL HEADER AND OIL TUBES (A) Pre-Erection. 2.14 In extreme position of runner blade stroke (fully open and fully close). 3.12 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. rotate the machine at very slow speed for checking any fouling between stationary and rotating components. Shaft and Inner top cover in erection bay check horizontality of the upper flange of oil tube (lower). shaft and Inner top cover along with oil tube (lower) in the turbine pit (Preferably after testing of Runner on erection bay). GUIDE LINES FOR ERECTION OF OIL TUBES AND OIL HEADER OF VERTICAL FRANCIS TURBINES 1. (i) Check that all items are available. below generator shaft to facilitate coupling of tubes. and in no case it should exceed the value of diametral clearance. After assembly of Runner. loosen the spigot suitably by grinding and assembly body to oil bath.11 Assembly oil bath and oil guide as per drawing. 5. correction to be done in respective flange face by suitability scraping or using shims taking care of ‘O’ seal grooves. Insert Middle tube inside Generator shaft in erection bay and then lower in the pit keeping oil tube projected by 200mm approx. 5. 5.10 If the throw is more than the value mentioned in Para 8 & 9 above. if required replace it. (ii) Clean all the components.central pipe bearing. (iii) Prepare all the "0" seals and check for damage/crack. 5. If the spigot between body and oil bath does not match. dowelling of oil header body and oil bath to be carried out.13 After checking free rotation and stroking of oil tubes. Upper flange of oil tubs (lower) should be parallel to turbine shaft coupling face.

and in no case it should exceed the value diametral clearances. 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. loosen the spigot suitably by grinding and assemble body to oil bath. 8. . 14. ENCLOSURES: Sketch No. dowelling of oil header body and oil bath to be carried out. centralize oil bath to get the uniform labyrinth clearances. In extreme positions of Runner blade stroke (fully open and fully close). and in no case it should exceed the value of diametral clearance. After connecting middle tube to lower tube and assembly of generator shaft with Turbine shaft check the horizontality of top flange of middle tube and throw of its spigot. If the throw is more than the value mentioned in Para 8 & 9 above. Assemble oil tube (upper). 15. 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. Centering of Center tube . Lower the assembly of central pipe and pressure box. . CHANGES DUE TO REVISION: NIL 16. correction to be done in Respective flange face by suitably scraping or using shims taking care of "O” seal grooves. 10. check throw of central pipe and pressure box.1 mm 2. check throw of spigot in generator tubular shaft and horizontality of top flange.15 (By rotational check). of the diametral clearance at central pipe bearing. 9. 4. rotate the machine at very slow speed for checking any fouling between stationary and rotating components. The allowable value of throw for point no. After assembly with upper tube. 11. If the spigot between body and oil bath does not match.5.6 and pressure box is preferably 75%. 5.within 0. of the diametral clearance at pressure bob bearing .within 0. Centering of oil Header . 7. 12. 13. 6. Lower and assemble generator tubular shaft with Generator shaft. value of throw for central pipe is preferably 75%. After checking free rotation and stroking of oil tubes. HTE/SK/001 & HTE/SK/002 Tolerance: 1.4. check the horizontality of its top flange and throw of the spigot. The allowable. Assemble oil bath and oil guide as per drawing.

GOVERNING EQUIPMENT
(i)

Pressure pumping set.

(ii)

Pressure Receiver.

(iii)

Hydro mechanical cabinet & runner control mechanism.

(iv)

Feed back mechanism.

Pressure Pumping set
(A) Pre - erection
(i)

Check all the pockets of foundation are as per drawing. Ensure sides of these pockets are
slightly rough for proper bondage of concrete.

(ii)

Chip the concrete to make it supporting surface level, if necessary.

(iii)

Check that all the blanking flanges are intact.

(B) Erection.
(i)

Lift the complete P.P. Set assembly on 4 equal wire Ropes, using eye bolts in fairly levelled
condition

(ii)

Install the P.P. Set as per drawing dimensions. Check the elevation at 4 places. Ensure no
gap exists between supporting brackets and concrete.

(iii)

Check the vertically by plum bob at pipe flanges.

(iv)

Fill the pockets by concrete and allow it to cure.

(v)

Check that motor is free, bearing is sound. Grease the bearings.

(vi)

Do not run the motor with out oil in the tank.

(ii) Pressure Receiver
(A) Pre-Erection .
(i)

Check that foundation pockets are as per drawing.

(ii)

Remove manhole door and inspect for any rusting from inside surface or foreign material
during Transportation. Check the paint condition from inside.

(iii)

Place the manhole door in the position if required replace the gasket.

(B) Erection.

(i)

Lift the pressure receiver in balance condition and assemble it on the foundation bolts. Align
the pressure receiver as per drawing dimension. Care to be taken that angular position of
the mountings are as per drawing.

(ii)

Check the verticality by pump bob on two planes.

(iii)

Mount all the fittings on receiver and prevent them from any damage (Glass parts/pressure
gauges).

(iv)

Pressure test the receiver with air and check leakage through any fittings.

Hydro Mechanical Cabinet & Runner Control Mechanism
(A) Pre-erection.
(i) Check all the items for any damage/breakage.
(ii) Clean the component cleanly.
(iii) Check the location and size of the pockets are as per drawing dimension.

(B) Erection.
(i)

Install the hydro mechanical and electrical cabinet as per the drawing.

(ii)

Use leveling screws to leveling screws to level and achieve elevation as per drawing.

(iii)

Check the verticality of the cabinets by plum bob and also check level, with precision level,
of the rod for free movement of kinematics.

Note :After installation of above panels dust/ moisture in this area should not be allowed. As such, all
precautions like chipping/cleaning in the surrounding are to be taken prior to installation of these
cabinets.
 Arrangement of PP set

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02210114201

 Arrangement of pr. 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.

(ii)

Wire rope be pre-stressed to 300 kg. . Force, for 24 hrs. before installation or as called in

drg.
(iii)

Wire rope joint to be made as suggested in technical requirement of the drawing.

(iv)

Touching of wire rope with any bracket, tube etc. is not allowed. Movement of wire rope
should be free.

(v)

All bearings be lubricated and wire rope greased before use.

(vi)

Kinks and broken stands in wire rope greased before use.

(vii)

Wire rope after installation should be in tension (not loose, to avoid any back lash)

(viii)

Sharp bends of wire rope to be avoided.

METERING AND INSTRUMENTS AND SHEAR PIN CONTACTS
A) METERING INSTRUMENTS
i)

Calibrate pr. Gauge, DTTT’s, RTDs, etc. called in drg.

ii)

Install metering instrument panel and assemble all instruments as per layout drawing.
Carryout laying, welding of pipes and install supports, clamping etc.

iii)

Dismantle pipes, complete cleaning by blowing air at 5-7 Kg atm.

iv)

Install all pipes and clamping arrangements with supports.

v)

Install pressure gauges on draft tube cone, penstock, spiral case and other instruments
as per layout drawing.
Note :
1. Carry out hydraulic testing of pipelines wherever called for.
2. 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. 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. The limit switches are
connected in series with normally closed contact.

C) ERECTION
i)

Install all base plates of unit switches, strikers and clamps as per layout details.

ii)

Assemble limit switches and strikers with their respective base plates such that the limit

Calibrate the Pressure Gauge.  Installation of metering instruments – 12100314201  Guide apparatus METERING AND INSTRUMENT PANEL 1. Gauges. providing a little additional allowances in the cable for flexibility. 4.switch remains pressed with striker and the contacts are closed. 2. DTT'S and RTDS as per the scheme. Calibrate DTT'S and RTDS 3. Wattmeter to be done. Wiring of the equipment to be done as per the scheme. lifting. iii) Carryout laying. clamping and connecting of cables with guide apparatus open. Voltmeter. Check and connect the pipe lines as per the technical requirement given in the drawing and document supplied separately by SUPPLIER Bhopal. iv) Complete sealing of glands to ensure water tightness. 5. 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 TRANSFORMERS RECEIPT OF TRANSFORMER AT SITE To ensure that a Transformer will function satisfactorily it is important that handling. Calibration of ammeter. Mount the Pr. 6. storing .

a sample of oil should be taken from bottom of the tank and tested to IS: 1866. When the transformer is dispatched filled with oil. Four jacking pads are also provided for lifting the transformer with the help of jacks. If necessary. A positive pressure indicates that the tank and the transformer components respectively are tight. If the dielectric strength is below 50KV. and at the final storing place before assembling. As a principle we never supply partly filled drums. In order to protect the active part against moisture. storing and assembling should be carried out. Drums containing transformer oil which have been dispatched separately should be examined carefully for leaks or any signs of tempering. Drums containing oil which have been dispatched separately should be examined carefully for leaks or any sign of tampering. and that the active part including the insulation materials is dry. the transformer tank is filled with nitrogen during transport at an over pressure of 0. the condition of packing and of the visible parts should be checked and possible traces of leaks verified (condenser bushings). in the form of channels having towing holes on both the sided & also holes for foundation of transformer. Lifting lugs for transformer lifting are painted red. For lifting purpose lifting lugs are provided on the top cover & on the sides of tank. Transformer should be jacked up using the projections specially provided for that purpose. level in transformer main tank should be checked & if the level is below the indicated level in main tank the same should be reported to the supplier immediately & also the same should be mentioned in LR copy. the transformers shall be inspected carefully for external visible damages as dents. For large Transformers it is recommended that the work is done by TARIL or is under supervision by experts from TARIL.and assembling are carried out with great care and cleanliness by experienced personnel who are thorough with various working operations. lifting. when tested on standard IS: 1866. UNLOADING The transformer should be unloaded by means of crane or suitable device of sufficient capacity (Please refer rating plate for weight detail). appropriate statements and claims should be made. Before unloading. Jack should never be placed . Check immediately the gas pressure at the arrival. When the transformer is dispatched filled with oil. All drums are dispatched filled up to their capacity and any shortage should be reported. DAMAGE/LOSS Damage or loss of any component should be reported to Supplier immediately. transformer should be immediately filled with dry Nitrogen gas at pressure of 2 PSI without loss of time. in case of possible damage/loss of any component. This section gives instructions how handling. If there is no positive gas-pressure. INSPECTION In connection with receiving and unloading at site. paint damages etc. Bidirectional skids are also provided on the bottom of the transformer. make the necessary claims with the contractor’s representatives under intimation to supplier so that such claims can be registered with the transport agents. After the arrival of the material at receiving points. All drums are dispatched filled up to their capacity and any shortage should be reported to us immediately.2kg/cm2 approximately at room temperature. Photographs or other useful evident should be submitted wherever possible. the customer should. Lifting lugs on the sided of tank are lifting the complete transformer. Check at lifting of complete transformer that the lifting wires/ropes are not in contact with bushing or other components on the cover. whereas the lugs provided on the tank cover should be used only for lifting the cover. the matter should be reported to supplier along with insulation resistance values of the various windings to earth.

ASSEMBLY OF WHEELS . To avoid undue mechanical stresses the transformers must be kept on reasonably level foundation.under any valves.

movement of transformer at site is carried out by mounting these wheels.Whenever wheels are supplied with transformer. .

. Pipes & Pipe supports. Heaters on Marshalling kiosks.Box R. the wheels shall be locked to prevent accidental movement of the transformer.T. mounting. Oil drums should be stored in horizontal (lying) position with both the bungs also in horizontal position. to the level marked. etc. In power transformer wheels are designed such a way that conservator side wheels are of slight higher in height fin the view of keeping transformer shortly inclined to release trapped air from main tank and to avoid accumulating rain water on the tank top cover. the dehydrating breather must be fitted on all the transformers which are oil filled.T. The provision of heaters is important and failure to provide them may result in extensive damage to the contents of the kiosk because of condensation. While fixing the rollers. When the transformer is in the final position. PRy. The breather incorporates an oil sealing device which must be filled with oil. should be operated at 6 monthly intervals. M. MOO. The tap changer. Relay. from Vertical Radiators & Conservator. Components like B. temporary heaters should then be installed to suit the site voltage. if provided. OUT DOOR STORAGE     Oil Drums: To be kept Horizontal and over two wooden planks. particularly during monsoons. Insulating Materials & Paints. should be kept energized.Mounting of wheels under transformer is to be done as per roller arrangement drawing. The condition of silica gel must be checked periodically. In case this is not possible the transformer shall be erected at its permanent location with conservator and breather fitted and dry oil filled to the correct level. INDOOR STORAGE The following items shall be stored indoor. Transformer placement can be with or without rollers as per applicable GA/foundation drawing. STORAGE        After arrival at site. Pressure gauges & Flow Indicators. Goods stored outdoors must not be placed directly on the ground. the flange should come on the inner side of the rails. If oil received in drums is not likely to be used immediately the drums should be stored in a covered space where the temperature variation is minimum. Cable Box.C. Cooling fans & Pumps. adequate protection must be provided at all times. All other accessories should be stored in a covered dry place. Dismantled equipment and components are packed to be protected against normal handling and transport stresses. Frames. If for this purpose.       All the Bushings. Rollers. Whether storage or in use. Care is taken that the caps shall be at 45 deg. it is desirable to erect and commission the transformer with minimum delay.C. Two of three runs from one end of the range to the other and back are sufficient. and should be covered carefully with tarpaulin or similar material. If it is necessary to store the oil outside. power supply at the appropriate voltage to suit the heater is not available. Breather. It should be ensured that there is no damage to the gasketted joints and that all the blanked joints are tight. & Motor Drive of OLTC. Turrets with C. to be effective.

Where walls are provided. tools. The transformers should always be separated from one another and from all walls and partitions to permit free circulation of air. Any spanners or other tools used should be securely tied with a tape so that they can be recovered. A transformer is best protected from damp hazard by circulating warm. Air inlets and outlets should be of sufficient size and number to pass adequate air to cool the transformer. the assembling of a fully completed transformer is carried out according to the following Instructions. exhaust fans can be installed for the purpose. pencils. The presence of loose fibers in suspension in transformer oil can reduce its insulating properties.INSTALLATION LOCATION AND SITE PREPARATION      Transformer should be placed on the foundation so that easy access is available all around and diagram plates. All components dispatched separately should be cleaned inside and outside before being fitted. oil gauges.. The inlets should be as near the floor as possible and outlets as high as the building will allow.. using soft non-fluffy cloth.g. valves.) shall be removed from the boiler-suit pockets etc. Check that there is no overpressure in the transformer when blanking plates or connection lids are to be opened. Check healthiness of all the accessories and components dispatched separately with respect to GA Drawing and packing list. if accidentally dropped. spectacles etc. All loose objects (tools. Provision should be made for the emergency drainage of the oil from the transformers (e. Transformer oil is inflammable and under certain circumstances in a confined space may become explosive. Tools with loose sleeves and tools with catches must not be used at work inside the transformer. ONAN type transformers depend entirely upon the surrounding air for carrying away the heat generated due to losses. If any cleaning or wiping is necessary this should be done with clean and dry oil. For indoor installation. ASSEMBLING THE TRANSFORMER By means of the Part list and the Transformer GA Drawing. Fibrous cleaning material should not be used as it can deteriorate oil when mixed with it. dry oil through it . shall be removed from the transformer cover before opening the connection and blanking lids. by surrounding the transformer plinth with sump filled with small pebbles. Workmen having access to the interior of a transformer should empty their pockets of all loose articles. Naked lights & flame should never be used near a transformer. nuts etc. therefore. it should be ensured that the transformer gets good ventilation as mentioned above for indoor transformers. Before starting the work through man holes. can be easily reached or read. the room must be well ventilated so that the heated air can escape readily and be replaced by cool air. in case of fire in neighboring apparatus or bushing or the transformer tank).shall be fastened to the wrist or another fixed point by means of cotton tape or string. All loose objects.g. thermometers. screws. The presence of loose fibers in suspension in transformer oil can reduce its insulating properties. Tools to be used inside the transformer/reactor -e. Where necessary. Adequate electrical clearances are also to be provided from various live points of the transformer to earthed parts. for tightening of screw-joints. The following precautions are to be taken:             Fire-fighting equipment shall be available near the oil-treatment equipment as well as at work on and adjacent to the transformer. etc.

This should be done before allowing external access to the interior of the tank. Tap changer. valves etc. this is checked with the megger after removing earth connection. . General conditions of insulation etc. Core-ground. Oil pump & all joints in the oil pipe work should be airtight to avoid entrance of air through leakage joints.      until temperature is 5° C to 10° C above ambient. Check Conditions of Leads. Check that the bushing leads set without being too close to ground or other points of different potential. The warm oil should be circulated as long as transformer is open to atmosphere. The active part (core and winding) should be exposed to the surrounding air as short time as possible. Before entering into a N2 filled transformer make sure that sufficient Oxygen is available inside. Connections. Open therefore only one blanking plate or connection lid at a time for remounting of bushings.

. a little every time so that uniform pressure is exerted on the gasket until the gasket is compressed to about 2/3 of its original thickness. Oil should be filled in tank under vacuum. the Tap Changer vacuum should also be released simultaneously. while evacuating the main transformer tank. While releasing vacuum. Transformer should not be left unattended during any part of drying out period. oil and grease To make a gasket joint. Do not open any blank flange for erection without filling oil up to top cover. otherwise gasket will get crushed. In case the transformer is provided with OLTC of in-tank type. Do not over tighten. rust. Gaskets are best stored in such a way. Bolts/studs should be tightened lightly and diagonally in the sequence. etc. first clean the metal surfaces ensuring that they are free from oil. . If the drying out process is carelessly or improperly performed. For this. one equalizer pipe should be connected between main tank and tap changer.GASKETS The sealing system normally used against oil and gas in transformers and belonging components has rubber bonded cork gaskets at joints. The vacuum pump of the filter machine should have capacity of creating vacuum as high as possible but not less than 710 mm of mercury. In case oil does not meet the requirement. the diverter switch compartment must also be evacuated simultaneously so that no undue pressure is allowed on the Tap Changer Chamber. Transformer of high voltage rating (66KV and above) have their tanks designed to withstand full vacuum. Transformer should be carefully watched throughout the dry out process and also observations shall be carefully recorded. Drying out process of transformer is requiring care and good judgment. It should also be ensured that the tap changer board. conservator. This may speed up the drying out process. The most practical method of drying out is by circulation of hot oil through a high vacuum filter machine incorporating oil heater and vacuum chamber. etc. it should be processed and shall only be used when meets the requirements. A set of new unused gaskets of correct size and thickness is supplied with every transformer for this purpose. that they must be protected from damp. are not subjected to full vacuum as these may not designed for the same. remove N2 gas from the tank by means of a vacuum pump and take full vacuum and check & rectify if any leakage is there & keep the transformer under vacuum for 12:00 HRS. Using one of the flanges as a template. Joints should not be subjected to pressure until tightening is complete. Whenever the blanking plates are removed to fix detached parts such as bushing turrets. Where possible. OIL FILLING Before filling oil in the tank. relief vent diaphragm. a new gasket shall be used while fixing the same. great damage may result to the transformer insulation through overheating etc. using the same gasket. scale etc. it is possible to break and remake a joint several times. Insert the bolts and tighten the bolts sequentially. DRYING OF TRANSFORMER USING FILTER MACHINE Before the drying out is started all fittings coolers and associated accessories shall be fitted. When filling a transformer with oil it is preferable that the oil be pumped into the bottom of the tank through filtration machine. The filling of oil inside the tank should be done under vacuum & fill the transformer main tank up to top cover. For transformers dispatched gas filled. punch the necessary bolt holes. a vacuum pump can be connected to the tank top cover to keep the oil in tank under vacuum consistent with tank suitability. and in handling the gasket. If care is taken in making joints. full or partial vacuum should not be applied without consulting manufacturer. Below 66KV class transformer. it should be tested to meet the requirements as per IS:1866.

It will be observed that in the beginning IR values drop down as the temperature goes up. Oil samples are taken out from them and tested. The circulation is continued till insulation resistance and oil samples test are satisfactory. Plot IR values taken at regular intervals against temperature readings. .Coolers and Tap Changers are filled with clean dry oil. Further circulation of oil is carried out till the oil results are satisfactory. The oil temperature as measured by the oil temperature indicator should be of the order of 60’C. The IR values will be low till moisture is coming out of the insulation and start rising before steadying. In no case temperature of oil inside the filter machine should exceeds 70’C.

The earthing connection should be of sufficient cross-section to carry the LV line current for 30 seconds. replacement of gasket and “o” ring should be done. the surrounding area should also be cleaned thoroughly as rust tends to spread beneath paint work. Earth resistance should be measured and it should be within acceptable limit. All radiator valves are also fully opened and locked in proper position.1 GENERAL CHECK POINTS 1. Buchholz relay is to be mounted in position inclined angle of 5 to 7 degree. If found necessary tighten. 6.EARTHING Tank should be permanently and effectively earthed by means of connection to the earthing terminals provided for the purpose at the bottom of the tank. The transformer and its equipment are cleaned carefully from dirt. Failure to maintain the paint work in good condition will result in considerable deterioration of the apparatus during storage or service. should also be earthed. A good low-resistance earth is essential for adequate protection. OLTC and Bushing turret to make ensure that no air remains inside the transformer tank. The touch-up paint should be limited to a surface as small as possible. winding neutrals etc. . buchholz relay. Failure to maintain the paint work in good condition will result in considerable deterioration of the apparatus during storage or service. Both damaged and surrounding surface should be cleaned so that all grease. radiators. Ensure arrow mark of relay towards conservator. Check the MOG operation by depressing the float. 5. If the paint work has been damaged during transit or erection. the surrounding area should also be cleaned thoroughly as rust tends to spread beneath paint work. If the paint work has been damaged during transit or erection. The surface to be repainted should be cleaned and free from rust and grease. it should be immediately arrested. If any leakage found. After completion of erection work it should be checked thoroughly that there should be not leakage. bushings. lubricating grease etc. The interposing valves between the radiators and the tank are opened. COMMISSIONING After completion of proper erection. After erection & oil filling. pumps motors and other apparatus. transformer should be checked for any oil leakages from each and every part. TOUCH-UP PAINTING A basic principle at touch-up painting should be to restore a damaged paint coat on a surface to the same quality and finish as of the surrounding surface. 2. 4. 4. Ensure that. Before putting transformer in service. touching-up should be carried out with the least delay. oil pump motors. Earthing terminals are provided on tank for earthing of tank mentioned in General Arrangement Drawing. transformer is to be kept ready for commissioning. Ensure that paint on the earthing terminal is removed before connecting the earthing strips. all the thermometer pockets are filled with transformer oil. Air release from all air release plug / screws on Main tank cover. Other such as wiring of various alarm/trip contacts. If rust has begun to form. oil. touching-up should be carried out with the least delay. fan motors. The surface to be repainted should be cleaned and free from rust and grease. Check the level of oil in main tank and OLTC conservator. 3. Valves between Conservator to main tank should be fully open. earthing of neutral and tank is also to be completed. dust and other impurities will be removed. Damages on the primer paint and grinding down to the steel surface should be painted with two coats anticorrosive primer paint. following check points and Testing should be done to ensure the healthiness of the transformer. COMPLETION OF ERECTION WORK Final topping up is now done up to a level in conservator commensurate with filled oil temperature. Other accessories such as fan motors. If rust has begun to form.

OSR. Check Valve between OLTC conservator and OLTC surge relay open. 11. AVR can also set as per required voltage variation. 14. Also the oil in oil seal to be filled up to the level indicator. Paint between earthing terminal and earthing strip should cleaned properly for better connectivity. 23. Apply touch paint at required places. 17. 22. Check weather transformer is earthed properly by two independent earth connections. 12. Buchholz relay. 15. Check oil level in OIP bushing from glass or small MOG (Mounted on bushing). Ensure that. Check terminal clamp on bushings and cable and termination on bus bars. WTI and MOG) should give proper alarm and trip indication.7.e. PRV. 24. Minimum clearance between live parts to earth should be checked as per drawing. Check BCTs for protection and metering connected to respective circuits properly. Marshalling box. Check Bushing thimbles and terminal cops tightness. 8. Check the various protective devices (i. Check the Buchholz relay practically by injecting the air from test cock or by draining the oil from buchholz relay by closing both side valves. Check Transformer painting. . Check Explosion vent assembly mounting. Check Name plate provided properly. Check the color of silica gel in breather is dark blue. 10. Check OLTC Explosion diaphragm in healthy condition. Check the incoming voltage and set the OLTC on the corresponding tap position. 20. Check Roller wheel stoppers provided. 19. Check the air passage of breather is not blocked. buchholz relay floats are not locked and the relay is set at the desired position. Check functions of the breakers with transformer actual tripping operation. 18. if applicable. Also OLTC. 9. It should be in required level. In case of off circuit tap changer brought to desired position and locked with bolt in plate hole. Check Anchor bolts for roller frames and cooler frame provided. OTI. 13. 21. cable box should also earthed properly. Also check for earthing for neutral bushings. 16.

The structures are similar. At the outer terminations of the incoming line and transformer bays.1. These interconnections are dimensioned to the rated current of the bays. Interconnections of single phase enclosures The continuous (equi-potential) enclosures of the single-phase enclosed busbars are interconnected at both ends. below the local control cubicles. .) 5. The interconnections are dimensioned to the rated current of the busbars. and in the cable cellar. The interconnections ensure the low touch voltage between the enclosures of different phases in the case of short circuit currents as well.Gas Insulated Switchgear Earthing The earthing system of the GIS is designed according to the IEEE Guide for Safety in AC Substation Grounding (ANSI/IEEE Std 80-2000). The substation earthing system includes the earthing grid. the cross section are the same as at the busbar ends. The earthing system of GIS needs several connections to the substation earthing system. which have to provide the low step voltage in the whole area of the substation. (The optimal positions are below the two endpoints of the LCC line. including the buildings as well. These indoor connection points shall be placed in the four corners of the GIS room. The earthing system of the GIS is not independent but a part of the substation earthing system. For this reason all metal parts of the substation buildings (mainly the elements of reinforcement) have to be welded in the crossing points to each other and connected in several places to the substation earthing grid. next to the triangular arranged cable sealing end enclosures the three phases are interconnected as well. Suitable connection points of the earthing grid have to be arranged close to each outdoor and indoor equipment and metal structure to provide earthing possibilities.

Gas handling The most important component of the GIS is the suitable insulating and arc quenching medium: the sulphur hexafluoride gas. The supplied gas shall meet the requirements of IEC 60376 (2005-06) and a certificate of compliance should accompany consignments. it can be liquefied by compression and is usually transported as a liquid in cylinders or containers. and includes the following jobs:  assembly of the steel support structures  mounting of the GIS from shipping units.759 MPa respectively.54 °C and 3. which were fitted up and tested in the factory before  installation of the local control cubicles  secondary cabling between GIS and LCC-s  establishing of the earthing system 7.2.Erection and commissioning 7. . Site erection of the GIS The site erection can start if all the civil works are ready. As the critical temperature and pressure of SF6 are 45.1.

1.3. greasing if necessary) 7.)  Proper function of the measuring. section drawings of the different bays)  Conformity of the secondary control and protection circuits with the manufacturer's drawings (schematic diagrams. protective and regulating equipment including the internal heating and lighting of drives and cubicles.7. alarm and position indication of each circuit breaker drive according to the manufacturer's instructions (operational tests).2. Checks and verifications After erection before the high voltage tests the GIS should have a final inspection.  Proper function of the interlocks operated locally from the local control cubicles. the gas-insulated metal-enclosed switchgear shall be tested to check the correct operation and the dielectric strength. The content shall not exceed the following limits after humidity measurement:  50 ppm (mass) for circuit breaker poles . To reduce the risk of moisture and dust entering enclosures so preventing correct operation of the switchgear. gas schematic diagram. cleanness. Tests after erection on site After erection.3. 7. The moisture content of the insulating gas shall be checked. Measurement of gas condition The gas filling pressure of each gas compartment shall be checked.3.  Proper operation and position indication of each disconnector and earthing switch drive according to the manufacturer's instructions (operational tests). layout. tightness of nuts and bolts. connection diagrams.  Proper condition of each gas insulated flange connection (wholeness. (The remote operation is to be checked together with the central control equipment. cable plans)  Conformity of the earthing system with the manufacturer's drawings (earthing plans)  Proper function of the direct current (DC) and alternating current (AC) auxiliary supply systems  Proper operation. before putting into service. no obligatory periodic inspections or pressure tests are specified or recommended when the gas-insulated substation is in service. The followings should be checked step by step:  Conformity of the primary switchgear with the manufacturer's drawings (single line diagram.

3. 100 ppm (mass) for other components 7. . Resistance measurement of the main circuit During the erection the resultant resistance of all bays (in each phase) between the busbar(s) and the outgoing terminal shall be checked. Gas tightness tests Leakage test with gas leak detector has to be performed around the flanges.3. The exact reason should be find and eliminate because it can cause overheating and failure later. The increasing of the resistance usually indicates some problem about the contact conditions of the tested part.3. The resistance shall be calculated from the voltage drop measured at 300 A direct current (DC) loading current: The resistance should be compared with the prescribed values and tolerances given by the manufacturer.4. during the work of the GIS. 7.

The housing of each earthing switch is insulated from the further part of the enclosure with a special disc. the closed contact of the second earthing switch and the enclosure between the earthing switches. special attention has to be made for the mechanical security of the connections. . These data have to be checked by primary current injection. which is necessary for the test. The measuring result shall be recorded in test report. The current injection circuit can be established during two closed earthing switches (maintenance or high-speed types). the bypass connection has to be replaced onto the earthing switch. which are placed on both sides of the tested current transformer. Considering the high current. The check has to be made phase-by-phase. The test shall be made phase by phase and the bypass connection can be removed only at the place tested. the current carrying bar between the earthing switches. In normal work this insulating disc is bypassed by a removable connection. for the proper contacts. The injected primary test current flows through the closed contact of the first earthing switch. To the tests this connection shall be removed from the first earthing switch. Checking of the current transformer cores The ratio and the polarity of each CT core have to be checked. for the placing of the connecting wires and for the proper earthing of the equipment.3. and the test equipment shall be connected to the connection points on both sides of the insulating disc. before the connecting to the other phase.5.7. After finishing the measurement.

7. Normally the dielectric test shall be made after the switchgear has been fully erected and gas-filled at the rated density preferably at the end of all site tests. . when newly installed. storage and erection. Dielectric tests on auxiliary circuits After the cabling works of the secondary system are completed.3. the dielectric strength shall be checked in order to eliminate any causes (wrong fastening. for checking the correct wiring the voltage test is to be performed with high voltage DC testing equipment. The neutral point connection of the tested AC circuit has to be removed during the above mentioned procedure. transportation. High voltage tests on the main circuits Since it is exceptionally important for the gas insulated switchgear. The high voltage site tests are supplementary to the dielectric routine tests with the aim of checking the dielectric integrity of the completed installation and of detecting irregularities. presence of foreign bodies. Such a dielectric test is recommended to be performed also after major dismantling for maintenance. etc.6.7.3.) which might give rise to an internal fault in the future.7. DC voltage has to be applied between the terminal blocks and the earth point. These tests are to be distinguished from the progressive voltage increase performed in order to achieve a kind of electrical conditioning of the equipment before commissioning. damage during handling.

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CABLE LAYING WORK General Instructions: This section describes general instructions to be observed during cable pulling work.. care shall be taken not to damage the cable. In removing lagging from cable reels. tags and labels. a) Handling of Cable b) At the time of acceptance and prior to installation. reel flanges and reel marking. Sweet sand (or backfill soil as required by project . asphalt. glass pieces. if not marked. staples or bolts from inside flange before unreeling cable. so as not to loosen the turns of cable on the reel. nails and pieces of concrete. brick pieces. This examination should also include lagging. sharp-edged objects etc. Correct Handling Cable Drums Cable reels that are to be transported on trucks must be securely blocked or anchored to prevent rolling. While handling cables. Before Cable Pulling 1) It shall be confirmed that trench floor or other places where the cable is to be installed are free from any foreign materials such as stones. If a reel of cable is to be rolled for any appreciable distance. The cable trench curves must be checked thoroughly. Such materials should be removed at least 30 cm away from the trench. Any water inside the trench should be pumped out completely. When rolling reels on the ground. it shall be rolled in the direction indicated by the arrow on the reel flange or with the outside end of cable trailing. to ensure that the minimum bending radius of the cable is attained. Care shall be taken to avoid damaging reel lagging in order that outer layer of cable remains protected. The trench wall must be secured appropriately in accordance with specification prescribed by the client. Remove all nails. they shall be carefully eased over any rough surfaces. which may damage the cable. the cable reel should be thoroughly examined for any outside physical damage or damage to cable end caps. Care is to be taken to prevent cable from dragging. necessary precaution should be taken to prevent damage to the cables.

The meeting prior to cable pulling is recommended to decide position of watchmen with communicative equipment to guide cable pulling works. intermediate post and the winch has to be established to effectively coordinate the work process. The rollers that are inclined towards the centre ensure that the cable is fed centrally into the trench. Whenever a cable is cut. drum brake. 4) Essential words or signals for cable pulling. mist or dripping or splashed water by heat shrinkable caps. must immediately seal the exposed area. Ravin recommends to conduct the DC sheath test on the reel in order to ensure that no damage has taken place during transporting and handling of the cable. are fixed and understood by all the associated staffs. The direction of pulling should be so chosen so as to require the least pulling strength at the end of the cable path. Whereas the cable rollers in bend portions shall be set as close as possible. The drum should be mounted on transport and laying trailer. Upon completion of the test heat shrinkable end caps. And it shall be confirmed that trench will not collapse at any portion along the cable route. Swivel shall be installed between wire rope and pulling eye to prevent the cable from twisting. It should not exceed the maximum pulling force of the cable recommended by Ravin. Watchmen shall be positioned every 50 metres and at every corner. In field practice anchor pins have proved ideal for anchoring the corner rollers.specifications) shall be evenly distributed on the trench floor with minimum thickness of 150 mm or to a thickness prescribed in the project specifications. to continuously monitor the cable pulling force. the cable drum shall be set at the opposite direction to the arrow painted on the drum that indicates the direction of rolling during transportation. at least START and STOP. rollers. For cable pulling. 3) Reliable communication between the drum. wire rope. 2) Prior to start of cable pulling. a cable guiding and bearer stand is positioned. to prevent cable sliding off. 7) When the cable is pulled into shaft or inclined tunnel. 5) It shall be confirmed that cable drum. 6) Final check of trench shall be carried out so as to eliminate the risks that may damage the cable. to protect against ingress of water or foreign particles. drum for wire rope and any other necessary tools/equipment have been set properly. . on curves. The rule for curves in the trench is that under no circumstances should they fall below the minimum prescribed bending radius of the cable (15 x ØD of cable). so as not to be subjected to the sidewall pressures partially. over which the cable taken off the cable drum is pulled into the trench. At the entrance to the cable trench. the head of the cable. Timbering/Shuttering shall be provided securely prior to cable pulling at positions where trench may or is liable to collapse. The equipment to be used should be of proven reliability and should be thoroughly tested before cable installation begins. Ensure that the winch has a pulling recorder and a tension meter. winch. the exposed end shall be sealed to protect from rain. Care should be taken not to damage the cable by battens when removing them from the cable drum. sufficient capacity of brake facilities shall be applied so that the cable may not slip down due to its weight. entrance to duct. Sufficient numbers of corner cable rollers are positioned on the curves in the trench. The cable rollers in straight portions shall be set at approximately 2 metre intervals to avoid the slack of the cable pulling.

Repair work shall be carried out if necessary. Any damage shall be repaired in a proper manner after careful examination. After Cable Pulling 1) The outlook of the cable shall be checked whether the cable has been damaged or not. vandalism and any other possibility to damage the cable. The integrity of sealing at the cable ends shall be confirmed to prevent water or any moisture entering the cable. Immediately after the first phase of backfilling and prior to final backfilling. which is an indication and proof of the correct laying. The pulling speed shall be reduced at corners. It is recommended to backfill the trench as soon as possible and not to leave the cable exposed. especially at bend portions and maintain sufficient clearance between existing services and the cable along the whole cable route all the time during cable pulling. After confirming that no damage has occurred at these portions. 4) The outlook of the cable shall be checked and it shall be confirmed that the cable has not been damaged during cable pulling. 3) Necessary protection to the cable shall be provided against mechanical damage. etc. DC sheath test at 10 kV for 1 minute should be conducted to ensure that no damage has occurred to the cable sheath during cable pulling. it shall be tightened again to the cable drum. must immediately seal the exposed area. in order to maintain the current rating capacity and to limit sheath current/sheath induced voltage of the cable and induced voltage on auxiliary cables as per designed values.During Cable Pulling 1) Maximum pulling speed shall be 7 m/min. 5) Power cables and auxiliary cables shall be arranged so as to keep the specified distance between them. 3) The pulling tension and the sidewall pressure should never exceed the permissible values. When pulling force exceeds the maximum permissible setting. the pulling should stop. The cable pulling should be stopped immediately on finding any damage and should not be resumed until the causes are removed. inlets of duct. in case of its occurrence. where the smooth pulling may be blocked. . 4) The cable end shall be raised up higher than the maximum water level expected. Upon completion of the test heat shrinkable end caps to protect against ingress of water or any foreign particles. These parameters should be recorded continuously on a recorder. The damage portion of cable shall be repaired as required. the pulling tension may be increased. 2) Watch the cable on the cable rollers. It is essential to be able to control the speed of pulling by monitoring pulling force speed and the length. 2) Integrity of anti-corrosive sheath shall be confirmed by carrying out DC high voltage test on it before and after backfilling. 5) When the inner end of the cable on the cable drum is loosened during cable pulling. Necessary action should be taken to eliminate the cause of damages.

e. causing breakdown of the drum flanges and in exceptional cases. The drum position should be chosen so that the longest length of straight trench is at the pulling end. with flanges horizontal. For guidance on handling. e.HANDLING Damage to cables can occur due to the incorrect handling to which the drums and cables may be subjected. Under no circumstances should a drum be rolled off a vehicle on to a cushion of sand. . and in such a manner as to leave sufficient space between them for air circulation. This action could crumple the flanges and barrel of the drum.2 Laying Normally cables are supplied on wooden or steel drums and great care should be taken during running off to ensure that the cable does not kink. driving splinters and/or nails into the cable. The cables should not be left unprotected. with any severe bends as close as possible to the drum.g. 3. provided that they are not bent or struck when at temperatures below 0°C. Check and tighten tie bolts on the drums at regular intervals.e. tarpaulin.. INSTALLATION 3. Cables should be protected from direct rays of the sun by leaving the battens on or covering the cables with thick black polythene sheet. which should be followed closely. In no circumstances must the drums be stored on the flat. the following points should be noted. the cable should be installed only when both the cable and ambient temperature are above 0°C and precautions have been taken to maintain the cable above this temperature. during installation (i.1 Minimum Temperature during installation To avoid risk of damage during handling. The site for storage of drums should be well drained. which will not allow the drums to sink and so give rise to damage due to the extreme difficulty in moving drums when they are sunk into the ground. i. the cable is immediately exposed to damage. prior to shipment or installation. please refer to the sketches and notes contained in this booklet. Once this breakdown of the drum occurs. should be scotched so that there is no danger of the flanges of drums coming into accidental contact with unprotected cable on other drums. All drums. the cables are suitable for operating at temperatures between below 0°C and the specified maximum limit. etc. 3. when the battens have been removed). All drums should be stored with the battens intact. Tier stacking of drums is not recommended. hard packed soil. STORAGE If any time the drums of cable are required to be stored for reasonably long periods. or preferably a concrete surface. movement of the drum barrel takes place. However.

reinforcing metalwork. if using power assistance. to protect the oversheath with a layer of bitumen tape applied with 50% overlap.mm of total conductor area can be applied (with the proviso of 2000 kg force maximum). Graphite paste should be used for lubrication when cables are being pulled into ducts. at all times. and paying out the winch rope. so as to keep within the maximum permissible pulling tension and to prevent the cable being flattened around bends or in ducts. comprises the installation of skid plates. the cable will settle between rollers and may cause high strain on men and machines during restarting. many loose turns can easily develop on the drum. etc. skid plates. Preparation of the trench. During stops. For such installations a pulling eye attached to the conductors is necessary. it is necessary for one man to be stationed at the drum with a plank of wood wedged against the flange of the drum so that over-running of the drum is prevented if the pulling stops. foundations. which could damage the cable. the drum will rotate in the opposite direction to the arrow on the “ROLL THIS WAY” marking. and for copper conductors a pulling tension of 6 kg force per sq.It is important that the rolling of the drum to this position should be in accordance with the arrow on the flange – to prevent loose turns from developing during unwinding. The distance of rolling should be kept to a minimum. Cable rollers are necessary to prevent the cable from touching the ground. rollers. a cable stocking can be used. This allows the leading cable rollers. etc. however. carefully observe the dynamometer to prevent overloading. . For open trench and straight installations. and should be spaced a maximum of 2m apart for normal size cables. prior to installing the cable. and for very heavy cable. It is particularly important to have a generous bending radius when cables are to be pulled by a power winch. On long pulls. The excavated trench should be carefully examined to ensure that there are no sharp edged stones. preferably by radio. The winch operator must. etc to take the load and settle under well-controlled conditions. Cables should never be bent to a small radius. The cable should preferably be drawn to its final position in a continuous manner. Correct positioning of rollers is important to keep friction to a minimum. When pulling by a winch it is advantageous for the cable end to be taken by hand as far as possible before attaching the winch rope. As large a radius as space permits should be adopted. Whether the pulling is manual or with a winch. more attention has to be given to the maximum pulling load which is permissible. As the cable is run off. Otherwise. Under no circumstances should the bending radius be less than the minimum permissible limits. Drums should be mounted so that the cable is pulled from the top of the drum. When pulling a power winch. it may be necessary to use a ramp to support the cable during the passage into the trench. It is advisable. good communication is essential. and riddled earth or sand should be used as a bedding.

because there have been cases of burned out connections due to failure to observe this precaution. However. accumulations of dust or copper filings and tools which may have been left behind. Obvious faults such as distorted panel work. When all erection and jointing work is complete the medium voltage switchgear must be inspected and thoroughly cleaned to remove cuttings of cable. it is dangerous to blow out equipment because dust. light metal scraps. Use a masking strip to prevent fouling by the floor materials. This means vertically and horizontally in both longitudinal and lateral directions. it should be level both front to back and should not vary by more than a millimetre or so between cubicle centres. Substations should be cleared out and locked fast and should not be used as a site office.ERECTION OF MEDIUM VOLTAGE (MV) SWITCHGEAR Before commencing erection of medium voltage (MV) switchgear check that all connections are tight on busbars and on main and auxiliary circuits. filings. dust or casual damage. ensure that they are correctly laid to an accuracy of about ±1 mm in 3 m. It is better to clean manually and vacuum the plant. After erection. Read and apply the manufacturer’s erection instructions and use the correct tools such as torque spanners to obtain the appropriate tightness of nuts. When the floor is being laid and there are no steel inset channels. steps must be taken to prevent deterioration of the switchgear due to damp. rags and sawdust can be blown into positions where they become inaccessible and may pass unnoticed. Examine the insulation carefully. washers. spare nuts. In the erection of the switchgear the following points should be emphasised. Where steel channels are used as foundations. . When the floor is being laid it is common practice to form pockets at the foundation hole positions in order to avoid having to cut them out of the solid floor at installation time. broken meter glass and damaged packing cases should be noted and immediate steps taken to rectify the damage or to return the switchgear to the supplier. store or workshop after the switchgear has been installed. Make sure switchgear is properly aligned.

and using normal geometric methods the switchboard and foundation bolt holes can be located. the traditional manual methods utilising jacks and roller bars are effective. Positioning of the cubicles should start near to the centre of the switchboard. A datum line requires to be established usually along the rear foundation bolts. building walls and other equipment in the room. Without the use of cranes. Lifting eyes are often either incorporated into switchboards or can be screwed into pre-machined holes. but generally slinging is necessary and this should be done strictly in accordance with the manufacturer’s recommendations. . building location. The method of positioning the switchgear is dependent on a number of factors such as switchgear size.The floor should be marked out in accordance with the switchgear assembly drawings usually provided by the manufacturer to ensure that the switchgear is correctly located with respect to cable trenches. Care must be taken not to exert pressure on weak parts such as control handles during this manhandling. Adjacent enclosures should be bolted together after they have been correctly aligned using whatever shimming proves necessary to make sure that the cubicles are vertically and horizontally true. When the first enclosure panel is correctly set the remaining enclosures should be positioned successively on alternate sides of this panel to make the front form an unbroken line. site accessibility and lifting tackle available. installing as early as possible the enclosures associated with any special chambers or trunking. The first enclosure should be positioned and checked to ensure the side sheets are plumb and that any runner rails are level in both planes. however. The fixing bolts should be positioned in the foundation holes and cemented in leaving adequate time for the cement to set before tightening up.

this should include measuring the insulation resistance and continuity of all cables and wiring including internal and auxiliary connections.Cable connection in cable panel A further examination of all incoming and outgoing circuit and auxiliary cables. Ensure that the top of the switchgear is free from all dirt and rubbish. phase rotation checks must be made before three-phase drives are energised. All cable boxes must be properly topped up and compound filling spouts capped off. A final check on all incoming and outgoing cable connections to terminals ensures that they are tight and have adequate clearance. should be done. All insulators and spouts must be clean and dry and cover plates securely bolted up with all screws in position and tightened and breather vents clear of obstruction. . and the operation and accuracy of meters and relays by secondary or primary injection tests should be checked. Dashpots must be filled to the correct level with the right grade of fluid. All moving parts must be inspected to ensure they are all operative. High voltage testing can then be carried out to the test figures laid down in the appropriate BS switchgear specification or as specified by the client’s engineers who should witness the tests and sign the test results.Checking of cable and other connections Si emens metal clad switchgear SIMOSEC . Where appropriate. including a test of the correctness of the connections at the remote ends.

After testing. . precautions must be taken to discharge any static and remove the test connections before bolting up any covers removed for testing. Before energising. particular attention being given to manual trip and close operations and to the operation of overcurrent relays and residual current devices. the operation of all circuit breakers and relays should be confirmed manually and electrically to ensure that no sticking or malfunction is present.

ERECTION OF E.O.T. CRANES
GENERAL:
An E.O.T. crane can be divided into different sections as follows:(a) Bridge girders,
(b) End carriages,
(c) Hoisting trolley also known as crab,
(d) Long travel machinery,
(e) Driver’s cabin/Floor operation.
ERECTION OF CRANE:The crane should be erected on an un-occupied floor where no industrial or construction work is
to be carried out during erection. The size of the floor must ensure free & convenient
handling of the crane during the erection period i.e. setting the crane in erecting position on the
floor, turning the suspended crane etc. the most convenient place for erecting the crane is the
space between the columns provided there are no horizontal bracings connecting the roof trusses.
the roof trusses used for lifting the crane should be checked for stresses during erection with a
dynamic factor of 1.2.
Besides testing the rope & trusses for strength, they should be tested for stability under horizontal
forces acting at right angle to the truss plane.
The winches employed for lifting the crane should be equipped with ratched stops. The wire rope
employed for erection must have tags indicating wire breaking forces
& should be free of defects, fractures, kinks etc. The minimum safer factor should be three.
When hoisting the crane or its parts the following conditions should be kept in mind.
(a) The angle of inclination of the slings should not be less than 45º.
(b) To prevent rupture of the rope due to sharp edges of lifted materials, wooden or metal lining
should be used.
(c) The number of clamps to be used for fastening the rope should be sufficient.

We should also ensure that the axes of the winch drum should be exactly at right angle to rope
direction.

Fig.:- Schematic View of E.O.T. Cranes.

LIFTING THE CRANE:Depending on the weight of the crane, the strength of the rope, trusses, the crane can be lifted
by one winch or two or four winches. If the weight of the crane is not very high the crane
structure can be assembled at the floor & the complete crane can be lifted. in case the crane is
very heavy we may lift different portions of the crane in sequence as follows:1. End carriages complete with L.T. wheels fitted in position.
2. Main girders.
3. Hoisting trolley or crab.
4. Driver’s cabin & other electrical components.
To simplify the positioning of the different components the crane should be match marked at
every joint. Every joint should be bolted only by means of machine bolts.
For the safety of the people engaged in erection work, the following safety rules should be
observed:1. When lifting the crane structure the dangerous zone of assembly must be protected with
flags barriers etc. & no un-authorised person should be admitted in the area.
2. Do not lift the crane if the erection area is badly illuminated.
3. Although the lifted structures should not be allowed to suspend for a long time but in case of
exception we must see that:(a) The safety factors of the ropes & cross girders should be twice than the normal working.

Client: Tato Hydro Power Private Limited, Mumbai
Proposal for EPC execution of Electro-Mechanical Works for 4 x 175 MW Tato – II HEP
and the 10 MW Dam Toe Hydropower Plant, Arunachal Pradesh
(Tender Specifications No. CPG/Tato-II/Package-3/EM/3A)

(b) The last line of rope running off the blocked should be clamped near the block.
(c) In case the load is lifted by means of hand winch, remove the handles, apply & secure the
brakes.
(d) Post workers to ensure security.
4.
5.

It is strictly forbidden to stand or walk under the crane when the crane is being lifted.
The scaffolds must comply with the safety rules. the fitter working on top, must handle the
parts & tools carefully so as to prevent them to fall down.

The erection supervisor must ensure that all the components are assembled in accordance to
the sub assembly drawings. after the crane has been fully erected, we must do the electrical
connection exactly as per its wiring diagram. Before we actually do the load test we must run
all the motions in idle condition. during idle running of different motions we should particularly
observe the following:(a)
Eccentric running of moving parts.
(b)
Alignment of shafts.
(c)
Fauling of moving components.
(d)
Any un-usual noise.
(e)
Presence of lubricant at desired surfaces.

After the idle running of different motions & satisfactory performance of motors, limit switches,
brakes & controllers we may go ahead with load testing of the crane in accordance to relevant
Indian standards.

If the contract for erection & commissioning of the crane is not given to the manufacturer of
the crane, it will be desirable to seek their supervision during Erection & commissioning. This
will ascertain the alignments of components & thus longer life of the crane.

Page 96 of 96

Open Joint Stock Company “Power Machines – ZTL, LMZ, Electrosila, Energomachexport”
(OJSC “Power Machines”)