You are on page 1of 24

STEAM TURBINE

500 MW
ERECTION PROCEDURE
ERECTION

CHECKING OF FOUNDATION BEFORE CASTING


Customer to provide, center line and elevation point.
Check positioning of all the inserts and fixed points with respect to center line
in transverse and longitudinal direction as per BHEL Hardwar drawings.
Check elevation of all points.
Check verticality of all the pipe sleeves with the help of plumb.
Ensure proper locking of all the insert and fixed points before grouting.
Ensure leveling on the fixed points of LP girder and LP rear pedestal.
Preserve machined surfaces of all the fixed points against any damages due to
Improper handling.
Ensure proper flatness of the bottom seating plate of all the inserts.
Ensure proper stiffeners in all the vertical and horizontal embedment provided
for various purposes like hangers and supports etc.
Ensure proper cleaning of the area before casting.
Remove all unwanted material.

NOTE: In case of spring loaded TG deck refer Installation Instruction


No. T1-08-0909G prior to positioning of inserts etc.

CHECKS DURING CASTING/POURING OF CONCRETE


Casting of foundation\TG deck should be carried out immediately after
inspection of the foundation\TG deck i.e. within 3-4 days after final
inspection to avoid any disturbance to the inserts and fixed point.
Ensure no disturbance to the insert etc. during pouring
vibrators are used.

Bharat Heavy Electricals Limited


Rev 00, 7-98

of concrete while

T1-08-0404G
Page No. 1 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

About 15-20 mm extra concrete may be left on top on all the pedestals and
LP base plate area for chipping/cleaning purpose at a later date.
Close all the pipe sleeve from top to avoid entry of concrete inside. Alternately
the pipe sleeve should be filled with sand.

CHECKING OF FOUNDATION AFTER CASTING


Clean complete foundation and remove all shuttering etc.
Ensure there is no loose concrete layer in the region where the pedestal and
base plates are to be laid. No repair should be done in this region
without consulting the turbine erection engineer.
Cover all the opening before checking any dimensional measurement to
avoid any accident.
Establish a suitable longitudinal axis considering the fixed point of the LP rear
pedestal and various pipe sleeves / inserts.
Establish a transverse axis as 90 degree with the help of the odolite.
Measure pitching/elevation of all the inserts and fixed points.
Measure elevation of all foundation on different pedestal and LP base plate
area.
Check level of LP rear pedestal fixed points and if required correction may
be carried out.

PREPARATION OF FOUNDATION FOR PLACEMENT OF


PEDESTALS AND BASE PLATES:
Foundation are to be cleaned and loose concrete are to be chipped off.
Maintain elevation of foundation
grout.

Bharat Heavy Electricals Limited


Rev 00, 7-98

to ensure correct thickness of non-shrink

T1-08-0404G
Page No. 2 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
A reference point for elevation in respect of machine center line (equivalent to LP
rear pedestal) is to be maintained at a proper place. This point is to be
preserved with proper protection. For making reference point a one side
ground plate of about 200 x300 x20 mm may be used. This may be
welded on a I-beam near Generator. The ground position of the plate is
to be kept on top side and all elevation are to be transferred from this
point with the help of water level jar. A correct elevation reading is
to be punched on this plate. This reference point is to be used only during
the turbine erection period.
Clean and deburr piping sleeves of the foundation on ID/OD

of the pipe.

Ensure all corners of the foundation remains perfect during chipping of extra
concrete of foundation.

PLACEMENT OF PEDESTALS
Open and clean the pedestal.
Ensure there is no paint/oil on bottom face of the pedestal sole plate.
Ensure there is no paint on inside surface or the pedestal and if required sand
blasting may be carried out at site.
Ensure correct fitting/clearance of locating rings of LP rear pedestal.
The half bore error of pedestals is punched by manufacturing unit however in
case it is not there, measure and punch half bore error of pedestal in
left/right
side of the pedestal. If the error is nil then this may be
punched as zero-zero.
Ensure that the pedestal parting plane is feeler tight after tightening all the
parting plane bolts. If required, colour matching may be carried out but
scraping/cutting is to be done on upper half cover only.
Check proper colour contact of spherical/cylindrical supports of the bearing
with the pedestal.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 3 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

Check

contact
between
spherical Torus piece
of
bearing
and
spherical/cylindrical seat. In case of any variation in contact no
scraping/cutting to be carried out at site and this may be referred to
manufacturing unit. Also refer T1-08-0808G. Check centering of individual
bearing w.r.t. pedestal seal bores by fixing pianowire on individual
pedestal.

Ensure cleanliness of all pedestal oil lines. Close opening of oil lines of
pedestal to avoid any foreign material entering in these pipe lines during
erection at site.
Weld MOP suction and discharge pipe lines in HP front pedestal as per the
drawing before placement.
Assemble protection sheet in the foundation bolt holes of pedestals.
Assemble anchor bolts along with anchor plate of the pedestals. Ensure that
there is good contact available to the backing
plate
with the
foundation. If required colour matching/grinding may be carried out to
achieve the contact.
Assemble protection sheet in the anchor bolt hole from bottom side of HP rear
pedestal foundation to avoid entry of grout metal.
Ensure level of both anchor plate of H.P. rear pedestal with 70-90 mm gap for
filling of grouting concrete.
Adjust height of the Anchor Bolts as specified in the drawing.

PLACEMENT OF LP BASE PLATE, OVER THE FOUNDATION :


Clean all the four base plates.
Mark/punch center line on the base plate as per drawing.
Ensure proper cleaning of base plate on bottom side.
Put identification marks on each base plate to avoid any mistake in positioning of
the same.
Do colour matching of all the eight nos. carrier plate on both the faces.
Match LP base plate with the individual carrier plate.
Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 4 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Place all the four base plates in position along with their leveling screws and
foundation bolts.
Provisionally align and level all the four base plates.
Assemble protection sheet in the foundation bolt holes.

ALIGNMENT OF PEDESTALS AND LP BASE PLATES


Provisionally align and level all the four pedestals including LP base plates with
reference to the earlier marked longitudinal and transverse axis. The
elevation reference is to be taken from the already positioned plate for
this purpose.
Align and level LP rear pedestal and set the elevation as per machine center
line.
Use piano wire arrangement with micrometer for centering of pedestal bore
and use water level jar for setting of elevation. Use measuring tape
to maintain pitching of the bearing from one pedestal to another.
Pedestals are to be set in level condition on both longitudinal and
transverse direction. Align and level HP front, HP rear and LP front
pedestals. Elevation of the pedestals are to be set as per catenary of
the machine considering the half bore error of the pedestal if any.
Align and level, LP base plates. Elevation of LP base plate is to be kept higher
than the rear pair of LP base plate in line with catenary of rotor.
After alignment of LP rear pedestal weld the locating rings as mentioned in the
drawing.
During welding of locating ring, ensure that there is no movement in the
pedestal in any of the direction.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 5 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

GROUTING OF PEDESTALS AND LP BASE PLATES


Fill 3 to 8 mm washed Pea-gravel in all the anchor bolts sleeves. These
gravel are necessary to give damping effect to the anchor bolts during
operation of the machine.
Seal anchor bolts holes after filling of gravel to avoid any entry of grout metal.
Medical tape may be used for sealing of these anchor bolt holes.
Clean foundation with compressed air.
Make shuttering of all the pedestal and LP base plates. Use thick polythene
sheet inside the shuttering to give better finish and avoid moisture
absorption by shuttering.
Shuttering should be made with maximum care to avoid any leakage of grout
concrete. All sides of the shuttering are to be sealed either with some
sealing compound or with thick mixture of grout material to avoid leakage
of grout material.
Foundation are to be kept wet for about 6 hrs. before grouting.
Non shrinkage cement duly approved by BHEL is to be used for grouting of
the pedestals and base plate.
Use fresh stock of the grouting material only and check the strength of the
material before use.
During grouting, the mixture has to be poured from one end only and it has to
flow to opposite end to avoid any blockage of air pocket.
Water curing is to be carried out for about 10 days duration.
All anchor bolts are to be stretched minimum after 21 days of grouting.
HP, IP & LP module placement work can be taken up after 24 hours of grouting
of the pedestal and base plates.
For individual pedestal and base plate, grout mixture should be poured in one lot
only.

PLACEMENT OF HP MODULE IN POSITION


Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 6 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Ensure matching of all the four palms of the module where it is resting on the
pedestals.
Ensure matching and parallelity of front and rear key block of the HP casing.
Assemble all four jacking screw of HPC and ensure their free movement.
Clean journals and coupling of the HP rotor.
Record journal dia, coupling hole sizes and spigot dia of HP rotor.
Lift module in level condition and place it in position by keeping it 3 to 5 mm
toward front pedestal side.
During placement of module use temporary packers similar to permanent and
additionally support it by four jacking screws.
Ensure load on all four packers with the help of some additional shims if
required.
Install temporary radial and axial keys of the casing.
Prepare HP rotor for alignment (Ref. section 20 before placing the IP module.

PLACEMENT OF IP MODULE IN POSITION


Ensure matching of all the four palms of the module where it is resting on the
pedestals.
Ensure matching and parallelity of front and rear key block of IP casing.
Assemble all four jacking screws of IP casing and ensure their free
movement. If these jacking screw holes are provided with the bolts
from factory then same are to be removed before placement of module.
Clean IP rotor on both sides including coupling and journal.
Record spigot /recess, journal dia, and coupling hole sizes.
Lift the module in level condition and place the module in position by moving
about 7 to 8 mm towards generator end. Use temporary packers for
placement of module in position and additionally support the module with
jacking screws.
Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 7 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Ensure load on all four packers with the help of some additional shims if
required.
Provisionally align the casing on front and rear pedestal bore.
temporary radial and axial keys of the casing with some shims.

Install

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

NOTE: In case IP module is sent to site in disassembled condition, refer


Instruction T1-08-0606G.

ASSEMBLY OF LP MODULE
This assembly can be divided in following sub assemblies:
Assembly of girder and end walls.
Assembly of LP inner inner and LP inner outer casing lower half.
Assembly / welding of LP outer casing.
Before starting assembly of LP casing in position, following works are
also to be completed :
- Positioning and welding of LP casing centering pin of front and rear
side.
- Positioning of key block of LP casing axial keys.
- Positioning of all internal of condenser.

POSITIONING AND WELDING OF LP CASING CENTERING


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

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 8 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Plumb the center line from LP front and LP rear pedestal bore on both side
over the square plate of the foundation.
Establish accurate position of the pin and put a punch mark at a required
height and mark a circle and a controlling circle over all the four sq.
Plates.
Dia of the circle must be equal to pin dia. A template equivalent to pin dia
has to be made for this purpose with about 20 mm thick plate and a
welded pipe for using as an handle. The template dia must be very
accurate and same may be made on machine.
Make precise hole with gas cutting/grinding to match template on all four
embedded plate. Ensure that the template is fitted with minimum
clearance and hole center are perfect as per marking.
Drill hole of about 10 mm dia on one of square plate of LP front and on one
plate of LP rear for air venting to avoid cracks during welding.
Insert both the pins and carry out the welding as per laid down procedure.
Before welding set correct axial position of the pins.
Insert key block on both the pins and weld their locking ring also. Ensure
proper clearances in key block before welding of its locking ring.
Preheating of 200 degree Celsius or more to be achieved before any
welding. Dye penetrate test on root run and after final welding is to be
carried out.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 9 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

ASSEMBLY OF GIRDER AND END WALL


Colour match side matching flange of girder with the surface plate.
Colour match seating flange of girder where it rests over the LP base plate.
Match and ensure parallality of axial key ways of girder.
Colour match side flanges of end wall.
Match and ensure parallality of key block of end wall.
Place left and right girder with carrier plate, spacer and lubrite packer on LP
base plate.
Provisionally align and level the girders. Set height of the girder equivalent to
machine center line maintaining catenary of the machine with the help of
water level jar arrangement.
Assemble locking plate of the front and rear end wall to facilitate its assembly
with the girders.
Assemble front and rear end wall with the girders and ensure perfect parting
plane level during tightening.
Align,

level LP outer casing and ensure contact of


matching/machining of spacer height.

packers by colour

Install LP casing radial and axial keys.


Assemble inner outer casing axial key blocks on left and right side of girder
and dowel them.
Lock with tack welding all the vertical joint bolts.
Put a seal weld run between girder and end wall joint all around except on top
face.
Weld girder and end wall parting plane joint with argon welding. Before
welding make a V groove with the help of a chisel and allow the
projection of material on surface. Do not make the groove by grinding.
Do colour matching with a surface plate on all four corner where argon welding
have been carried out.
Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 10 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

ASSEMBLY OF LP INNER INNER AND LP INNER OUTER


CASING LOWER HALF
The LP inner inner casing lower half is received from factory in assembled
condition with LP inner outer casing lower half.
Clean the casing and check all the threaded holes.
Do colour matching on all four corners of the casing where it rest over the
girder.
Colour match all eight carrier plates of inner casing on both side.
Assemble all carrier plates on girder and
individual carrier plate.

do

the

colour matching with

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

for

Level and lift LP inner outer casing and assemble/weld both the gusset plates
with the help of some temporary support.
Lower the casing in position over the carrier plates fitted with spacer and lubrite
packer.
Provisionally align the casing radially and axially.
Support the gusset plate with the help of screw jack (about 10-15 tons) on front
and rear side by taking support from condenser stiffeners. Screw jack is
to be unscrewed after box-up.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 11 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

Adjust the height of the LP inner outer casing as per center line of the machine
and then level it with the help of water level jar arrangement.
Ensure that all the eight packers have good contact. Loading of each packer
is to be ensured.
Lower the casing by about 2 mm on all the eight packers with the help of shims
for placement of LP rotor to avoid any fauling during placement of rotor.
Fit and weld all gusset plate stiffener pipes except pipe between LP inner
outer casing and condenser. Do not make any weld connection
between condenser and any of these stiffeners till neck welding of the
condenser is over.

PLACEMENT OF LP ROTOR
Measure journal dia, spigot dia and coupling hole sizes.
Ensure centering of temporary bearing support in the LP front pedestal for
placement of LP rotor.
Place LP rear bearing in position.
Prepare shaft seal compensator along with gaskets (Gasket to be installed in
fully ring shape only ) and position them on LP rotor with the help of
supplied supports of compensator.
Lift LP rotor with the supplied lifting beam in perfectly level condition and
place it in position. During lowering of rotor ensure radial clearance
with the help of long feeler gauges in the LP casing.

WELDING OF LP OUTER CASING


The welding of LP outer cover is to be carried out before placement of LP
Rotor in position to avoid damage to the rotor.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 12 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Colour match and remove all high spots of the matching flange of the LP
outer casing.
Ensure good contact between parted diffuser of LP front and LP rear cover.
Colour match and remove all the high spots of the parted diffuser/vertical face
to ensure good contact with the compensator at a later stage.
Colour match and remove all burrs and high spots from parting plane of LP
outer casing.
Side flange of LP front and rear cover are to be ensured in right angle to
achieve good contact with their matching flanges.
Place LP front LP rear cover along with parted diffuser and ensure feeler tight
joint after tightening the parting plane bolts. The joint must be feeler
tight just after normal tightening of bolts. Do not over tighten parting
plane bolts.
Ensure matching of parted diffuser face on both side of LP casing. If necessary
colour matching may be carried out to achieve a feeler tight joint.
Drill/ream all the parting plane holes as per drawings and install all dowel pins.
After

fixing of LP front and rear cover measure the dimension for


positioning of both the center flanges. The dimension are to be recorded
in such a way that there is no clearance after fitting of center flanges in
position on both side with the LP front and rear cover. The center
flanges are supplied in extra length on both sides from the factory and
final length are to be maintained at site only.

Drill/ream dowel pin holes in center flanges and install all dowel pins in position.
Ensure drilling and reaming of all dowel pin holes to equal depth.
Fit both the center pieces of the cover in position.
Achieve the fitting clearances for welding as per laid down procedure.
Weld/lock LP upper half flange with respect to lower half casing with the
help of metal cleats to minimise the distortion during welding of LP
cover. The cleats may be welded at an interval of about one meter
distance.
Carry out the welding as per the following welding procedure.
Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 13 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

WELDING PROCEDURE
Tack weld the crowned seam joint. permanently welding approx. 100 mm at the
generator end of the joint.
Opposite tack welded radial joint 2, permanently weld approx. 100 mm of the
crowned seam joint, pos. 1, staggering the two weld ends to ensure a
perfect transition when the crowned seam joint is finish welded.
Tack weld the crowned seam joint at regular intervals with a tack of 5T and pitch
of 25T.
When welding radial joint 2, shell plates 1 & 2, tacked together, rest on but are
not tacked to the retaining strip in the region of joint 1, so that any
shrinkage occurring during welding of seam 2 is not obstructed.
The tacking & welding sequence applies for all shells courses.
Weld radial seam at TE according to welding sequence plan.
Align, adjust and tack weld radial seam at GE.
Weld radial seam at GE according to welding sequence plan.
Weld crowned seam joint.
Align shell courses on joint strips and tack weld,
Weld on joint strips from center & ends of shell plate.
Insert pins in top half casing, release top half casing and lift to insert and tack
filler piece between joint strips.
Unbolt top half casing and lift in order to weld and finish - machine filler pieces in
the region of the joint surface.
Check welds according to specifications.

ALIGNMENT AND COUPLING OF LP-IP & HP ROTOR


LP rotor is to be aligned on pedestal seal bore and LP inner outer casing is to
be centralised in such a way that enough clearances are available to LP
rotor, during alignment. Now this alignment activity of all the three rotor can
be divided as below :
Bharat Heavy Electricals Limited
T1-08-0404G
Rev 00, 7-98
Page No. 14 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Preparation of HP rotor for alignment.
Preparation of IP rotor for alignment.
Preparation of LP rotor for alignment.
Alignment of LP-IP & HP rotors.
Reaming, honing of the coupling holes.
Balancing of coupling bolts weight.

PREPARATION OF HP ROTOR FOR ALIGNMENT


Align HP rotor with reference to front and rear pedestal seal bore reading. If
required move complete HP module along with the rotor.
Fix temporary radial and axial key of the casing on both front and rear side of
the casing. Remove HP front upper half transportation device.
Lift

module by 0.20 mm on front side by putting


packers.

additional shims in front

Insert HP front bearing in position.


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

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 15 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

Remove HP front lower half transport device gradually and ensure no


movement between HP casing and rotor. If necessary adjust shims of
HP casing front packers.
During loading of bearing always ensure that the rotor is not fouling inside the
casing with the shaft seals. This may be ensured by checking with feeler
gauge also.
Check axial position of HP rotor in front side on left; right and top position
from the rotor reference point to the HPC as given in the shop protocol.
Insert and load the bearing in HP rear end in similar way as carried out in
case of HP front end and record axial position of rotor as per shop
protocol.
Lock axially HP rotor with some fixture along with the arrangement of
jacking screw for movement of rotor. This fixture may be mounted on
rear pedestal. Before locking of rotor ensure axial position of the shaft.
Center HP shaft with reference to HP casing front and rear spigot. If necessary,
move the casing readily to achieve the centering. A fixture can be
fabricated at site for mounting the dial gauge on both the end of the rotor
to check the centering of the shaft.
Use thick oil during rotation of shaft on the bearing.
Protect bearing from any of the dust particles. It is recommended to place
upper half of bearing in position to avoid dust and any other damage to
the shaft journal.
Realign the rotor shaft with respect to pedestal seal bore and if necessary
adjust the shims below spherical support of the bearing.
Care should be taken during alignment that radial and axial clearances
between rotor and casings does not get bridged.
Check HP rotor radial run out on journal and coupling.
Check axial run out on thrust collar and both the coupling faces of HP rotor.
Check axial float of the rotor. Compare values with shop protocol values. (Ref.
T1-08-0802G). Deviations to be reported to Manufacturing Unit.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 16 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

PREPARATION OF IP ROTOR FOR ALIGNMENT


The IP module is also to be prepared in line with the HP module. However
as IP rotor is provided with one side bearing and opposite side is coupled
with the HP rotor without a bearing, extra care is necessary during
alignment of rotor in IP casing. The additional point which are to be taken care
are explained below :
Place

IP rotor rear end on bearing similar to the HP


transportation device.

rotor and remove

Provisionally align HP/IP rotors and couple on temporary bolts by moving both
the modules. During coupling of the rotors, the transportation device of IP
front end is also to be taken out.
Check axial position of rotor w.r.t. IP casing and adjust as per shop protocol.
Check centering of IP rotor front and rear end w.r.t. IP casing (similar to the HP
rotor centering check).
Check float of the IP rotor. Compare values with the shop protocol values. (Ref.
T1-08-0802G). During checking of float ensure HP casing is not fouling
with HP rotor. If required HP casing may be moved axially for this
purpose.
Check facial runout on IP rear coupling face and radial runout on journals and
couplings.

PREPARATION OF LP ROTOR FOR ALIGNMENT


Provisionally align LP rotor in pedestal seal bore placing the front end of shaft
on auxiliary bearing and rear end on bearing.
Align LP inner outer casing radially with the help of long feeler gauges and
install temporary radial keys in the gusset plate.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 17 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

Record all the radial and axial clearances of the LP casing without coupling
the LP-IP rotor. Variation if any in radial or axial clearances are to be
corrected/approved at this stage.
Remove shims from the front end of auxiliary bearing and keep rotor on lifting
tackle.
Record radial run out of LP rotor coupling and journal and axial run out of the
coupling faces of the both end.
Record float of the LP rotor by moving the LP inner outer casing lower half.
After ensuring the radial and axial run out of the LP rotor the LP inner outer
casing can be boxed up. Parting plane bolts of LP inner-inner casing are
to be heat tightened.

ALIGNMENT OF HP, IP AND LP ROTORS


Ensure radial and axial runout of all the three rotors are individually in order. If
necessary individual rotor module can be taken out for correction of
coupling face runout. Any variation on radial runout of rotor is to be
referred to the factory.
Match coupling faces of two rotor as per the axial face reading of the rotor.
Ensure that the higher point of the rotor coupling face and lower point of
another rotor coupling face are matched together. This is to be compared
with shop protocol also.
Preliminary align radially and axially all the three rotors and shift them in spigot
along with the casing to avoid fouling of rotor inside the casing.
During alignment achieve left and right movement of the rotor with the help of
shims in spherical / torus piece of the bearing. The up and down
movement of the rotor is to be achieved with the help of shims in the
cylindrical/spherical support of the bearing . The adjustment of shims in
the bearing should be within the permissible limits only.
Ensure during alignment that the catenary of the shaft is maintained.
Check/record spigot clearance of HP-IP and LP-IP rotors by actually moving
them in spigot.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 18 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Install four nos. supplied bolts along with one/two pins in HP-IP and LP-IP
coupling. Hand tighten the coupling bolts by keeping a gap of > 1.00
mm in coupling faces for alignment.
Rotate the rotor system and record the coupling gap at 90 Deg. interval on
left, right and top position. Ensure that the coupling, bolts and pins
remain free while recording the gap of the coupling for the alignment
purposes.
Check swing check value of the HP rotor with alternate bolts in position. The
above value must be within the prescribed limit only otherwise a
correction must be carried out at site in consultation with designer.
Ensure free movement of rotor on their bearing. Do not rotate the
is tight during its rotation.
Ensue that the coupling holes are
enlargement of holes.

rotor if it

properly aligned to avoid unnecessary

Ensure HP-IP-LP rotor radial run out after tightening with alternate clearance
bolts. Release the couplings for reaming / honing of couplings.
In case of spring loaded TG decks, refer alignment procedure
0909G

T1-08-

REAMING / HONING OF COUPLING


Ensure that there is no disturbance on coupling during reaming/honing
operation.
First ream/hone two opposite holes of the coupling and install two pins/bolts
with sliding fit and then take up all other holes.
Enlarge coupling holes to the minimum possible diameter and try to make all the
holes to same dia.
Ensure that the finished holes are straight and there is no banana shape. This
can be ensured by checking hole with a straight ground finish pin having
0.02/0.03 mm clearance.
The length of the pin should be equal to the bolt length. In case, few holes have
gone considerably over size during reaming/honing at site/works, do not
enlarge all the holes. As a special case in such cases these few holes
may be left as oversize.
Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 19 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Ensure that the holes during reaming/honing are perfectly finished as ground
bore and size obtained should be within 0.005 mm. Ensure all the
coupling bolts are fitted within 0.02/0.03 mm clearance with sliding fit and
bolts are to be ground within an accuracy of 0.005 mm.
Coupling bolts are not to be hammered in the holes and these are to be fitted
with thumb pressure only.
Do not decouple the coupling in any case without ensuring the fitting of all the
coupling bolts.

BALANCING OF COUPLING BOLTS


After fitting the coupling bolts in all the holes these are to be balanced within 5
gms accuracy and an accurate balance which can take a load of about 20 kg.
may be used. During balancing of coupling bolts following points are to be
taken care.
Final balancing of the coupling bolts are to be done along with the coupling
nut of individual bolt.
If all the coupling bolt hole sizes are same before/after reaming and honing
then all the bolts can be kept of equal weight.
If necessary adjust the weight of the bolts by machining the metal from the bolt
head.
When the holes of the coupling are of different sizes then it must be seen that
whether excess enlargement have been done at site or works. In such
cases if excess cutting have been done at site in a particular hole then
coupling bolt with excess weight are to be used. The amount of excess
weight must be equivalent to the excess enlargement of hole at site. If a
particular hole of excess dia. is noticed from factory then it is assured
that the particular rotor is balanced with excess dia hole and there is
no need of providing excess weight bolt at site.

COLOUR MATCHING OF THRUST BEARING


After completion of reaming/honing and preliminary tightening of the coupling
bolts, the colour matching of the thrust bearing pad have to be carried out with
respect to the thrust collar of the HP Rotor. During colour matching a good
contact on all the pads of front and rear side are to be ensured with respect to
Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 20 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
rotor collar by moving the rotor in +/- direction during its hand rotation.
Following points are to be taken care during colour matching.
Thrust bearing must be axially locked with the help of axial keys during the
colour matching of the pads. Axial keys to be fitted while finalising the
alignment of thrust bearing with rotor collar without pads.
Few drops of oil is to be put on journal portion of the thrust bearing during
rotation of rotor to ensure that the oil is not entering in pad portion of the
bearing.
Colour is to be applied on the thrust collar of the rotor.
If necessary move the spherical support of the bearing pedestal to ensure the
equal thickness of the pads before fittment of axial keys of the bearing.
During moving of the spherical support in front or rear direction ensure that
there is no left - right movement to the support otherwise that may
cause misalignment of the bearing.
After colour matching of the thrust pad the axial zero position of the rotor is
achieved and this can be taken for all other future reference for setting of
axial position of HP, IP & LP casing.
HP, IP and LP lower casing are to be set axially after fixing the axial position
of the rotor and their final axial keys can be installed at this stage.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 21 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

ALIGNMENT OF HP, IP & LP CASING


After completion of colour matching of the thrust bearing pads the casing
alignment work can be taken up. The following points are to be taken care
while aligning HP, IP and LP casing.
The roll check have to be carried out in HP, IP and LP casing to ensure the
correct radial clearances of the casing.
TG deck springs are to be kept in floating condition while recording the roll
check of LP casing. However the roll check of HP/IP casing may be
carried out before floating of TG deck for fitting of their radial keys but up
and down roll check of HP/IP casings are to be done with TG deck in
floating condition as per the procedure TS/ST/ 01/0008/00/96.
Ensure that there is no obstruction in the movement of LP inner casing due to
welding of any of extraction piping. The one of the joint of extraction
piping may be left free till completion of roll check of the casing.
The welding of steam inlet pipes between LP inner casing and LP girders are to
be taken up after completion of roll check of the casing.
HP, IP and LP casing are to be fitted with final packers and axial key immediately
after the roll check. During fitting of casing axial keys and palm packers
ensure proper contact on lubrite coating of the keys/packers to avoid any
damage of these coating during operation of the machine,
After completion of fitting of final keys and packers only the casing are to be
cleared for further works of welding of various pipe lines.
The gland steam, balancing leak of lines, steam inlet and exhaust pipes are to
be welded with HP casing after fitting of final axial keys and packers of
the casing.
Center HP rotor w.r.t. casing front and rear spigots. Compare the readings with
shop protocol and record the readings.
Offset center line of the HP, IP & LP casing w.r.t. respective rotor center line as
per recommended logsheet.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 22 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION

Check/record LP diffusers centering readings after roll check of the casing.


Before roll check of LP casing all the stiffener pipe welding work must be
completed. Refer T1-08-0909G.

FINAL TIGHTENING OF COUPLINGS


In case of spring loaded foundation after completing all other works the HP / IP ,
IP/LP , LP/GEN , GEN/EXCITER couplings are to be reopened and realigned
after completing the reaming /honing . The rotors alignment are to be checked
with TG deck in floating condition
as per the laid down procedure. After
checking of alignment /catenary the final couplings are to be tightened
including their coupled run out and swing check of rotors on HP front and
Exciter end of the shaft.

BOXING UP OF LP INNER INNER AND LP INNER OUTER


CASING
The boxing up of LP inner inner and LP inner outer casing can be taken up
before starting the alignment of HP-IP & LP rotor for coupling work. The
following points are to be taken care before/during boxing up of these two
casings.
Ensure matching of all the parting plane holes, fitting of
accessibility of spanner .

cap nuts and

Ensure feeler tightness of the parting plane joint of both the casing.
Check/record all the radial and axial clearances of the casing.
Ensure proper cleanliness of the LP inner inner and LP inner outer casing.
Ensure adequate clearance between LP inner inner casing and LP inner outer
casing to avoid any obstruction during expansion of the LP inner
casing inside the LP inner outer casing during operation of machines.

BOXING UP OF LP OUTER CASING


Bharat Heavy Electricals Limited
Rev 00, 7-98

T1-08-0404G
Page No. 23 of 24

STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
During the boxing up of the LP outer casing following points are to be taken
care.
Roll check of LP inner casing including the fitting of key, packers etc. must be
finished.
All the works must be finished inside the LP casing before boxing up of LP
casing including LP extraction pipe line works.
Ensure matching of all parting plane holes and feeler tightness of the joint
before boxing up of the casing.
Ensure feeler tightness of bursting diaphragm flange joint before boxing up of
the casing.
Ensure proper assembly of parting plane rubber cord.

FINAL HORN DROP CHECK


After completing the welding of HP inlet, HP exhaust, IP inlet, IP exhaust and other
piping of HP/IP casing the final horn drop readings are recorded as per the laid down
procedure mentioned in the manual for horn drop check. However the IP casing horn
drop is also to be recorded with IP inlet upper half pipe welded with casing alone.

Bharat Heavy Electricals Limited


Rev 00, 7-98

T1-08-0404G
Page No. 24 of 24