0000868254

OPERATION & MAINTENANCE BOOK WP4110 & WP4140
Operation & Maintenance Book

WP4110 & WP4140
Steam Turbine
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en HTGD 693 000 V0140 A

1
Revision History
�nderung Inhalt der �nderung
Dokumentseiten,
gesamt:
A New revision of chapter MAV/MAX - HTGD090117V0001W - Lubricat-
1906
ing and Control Oils for Gas and Steam Turbines
2 HTGD 693 000 V0140 A

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Operation & Maintenance Book
WP4110 & WP4140
Steam Turbine
Contents
Operation & Maintenance Book WP4110 & WP4140 Steam

Turbine ........................................... 1
MA - HTCT692560V9000 - General Safety
Rules........................................................................ 7
MA - HTGD693028V9005 - Introduction to the Steam Turbine Plant Multi-shaft unit in
a
combined cycle power
station ...........................................................................
................... 23
MA - HTGD693027V9005 - Technical Description of the Steam
Turbine .................................. 31
MA - HTGD690038V0001E - Outage Preservation of Steam
Turbines..................................... 75
MA - HTMD690133V0001B - Removing Salt and Silica from Steam
Turbines .......................... 87
MA - HTGD090550V0001F - Evaluation of Vibrations in Steam Turbosets > 50
MW.............. 103
MA - HTGD090486V0001G - Steam Purity Requirements for Turbine
Operation ................... 115
MA - HTGD690147V0001A - Endoscopic Inspections of Steam
Turbosets............................. 125
MA - HTGD090269V0001F - Permissible deviations from the nominal
speed.......................... 133
MA - HTGD090440V0001H - Permissible Deviations of the Steam Pressures and
Temperatures from the Rated
Values ............................................................................
.... 139
MA - HTGD090185V9000A - Insulation mats on steam
turbines ............................................ 147
MA - HTGD090185V9001A - Spray insulation on steam
turbines........................................... 157
MA - HTGD090185V9002 - Pipe
insulation ........................................................................
...... 169
MA - HTGD090387V9000 - Balancing of the Turbine
Rotors.................................................. 181
MA - HTGD090325V9000 - Hydraulically Prestressed Foundation
Bolts................................. 191
MA - HTGD090028V0004B - Rotor Raising Device for turbine & generator
rotors .................. 199
MA - HTGD690555V0001A - Suspension
Device .................................................................... 207
MA - HTGD090319V9000 - Rotor Lifting
Device ...................................................................... 215
MA - HTGD693015V0001 - Holding Device for hydraulic tensioning
cylinder.......................... 223
MA - HTGD690059V9000 - Disassembly and Re-assembly of the Expansion Sleeve
Coupling ..........................................................................
................................................... 231
MA - HTGD691538V0004A - ITH Torque Wrench Equipment Type
DR .................................. 265
MA - HTGD691538V0005A - ITH Bolt-Tension
Equipment..................................................... 287
MA - HTGD690148V0001B - Isolating
Valve............................................................................
345
MA - Illustrated Parts
Catalogue..........................................................................
...................... 351
MA - Test
Certificates/Datasheets ...........................................................
.................................. 459
MA - Instrumentation
List...............................................................................
............................ 883
MAA10/MAC10 - HTGD693011V9020 - Disassembly and Re-assembly of the HP/LP
Turbine
Block .............................................................................
...................................... 1349
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OPERATION & MAINTENANCE BOOK
WP4110 & WP4140
MAA10CT005/010- HTGD693029V9001 - Temperature

Sensor ........................................... 1625
MAA12 - HTGD690520V9008 - Swing Arm
Supports ............................................................ 1631
MAC10 - HTGD690082V9000 - Rupture
Diaphragm ............................................................. 1639
MAC31- HTGD691780V0001A - Low Pressure Butterfly-Type
Valve.................................... 1645
MAC31- HTGD691780V0101D - Low Pressure Butterfly-Type Valve Technical
Instructions.......................................................................
................................................ 1655
MAC80 - HTGD690182V9000 - Constant Pressure
Valve..................................................... 1693
MAD21 - HTGD690143V9014 - Combined Two Collar Thrust and Journal Bearing with
jacking oil
connection ........................................................................
............................... 1705
MAD51 - HTGD690524V9026 - Pocket-Type Journal Bearing with jacking oil
connection..... 1721
MAD51 - HTGD693038V9009 - Disassembly and Re-assembly of the LP Internal
Bearing............................................................................
................................................. 1735
MAK80 - HTGD691883V9000 - Rotor Turning Gear -
WDE6016 .......................................... 1767
MAV - HTGD693010V9024 - Technical Description of the Lube and Control Oil Supply
Systems with integral pressure generation for the jacking oil
system.............................. 1793
MAV/MAX - HTGD090117V0001W - Lubricating and Control Oils for Gas and Steam
Turbines Specification and
supervision........................................................................
.... 1811
MAX11- HTGD690411V9000 - Constant Pressure
Valve ...................................................... 1831
MAX43 - HTGD690743V0001A - Trip Unit 2-out-of-3
relay ................................................... 1841
MAX43 - HTGD690744V0001C - Sequence
Valve ................................................................ 1847
MA - HTGD691892V9000 - Decommissioning & Disposal Guideline for ALSTOM
Steam
Turbines...........................................................................
..................................... 1855
MA - HTGD
Index .............................................................................
....................................... 1897
MA - KKS
Index .............................................................................
.......................................... 1901
4 HTGD 693 000 V0140 A

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Operation &
Maintenance Book
WP4110 &
WP4140
Steam
Turbine
Additional Documents
1BSE001405B - P & ID Steam Turbine / 1BSE501022B - Legend to P & ID Steam Turbine
1BSE001715A - P&ID LUBE OIL PURIFIER / 1BSE501424A - LEGEND P&ID PURIFIER
1BSE001373A - LOCATION OF INSTRUMENTS
1BSE001374 - SHIPMENT INFORMATION
1BSE001375 - TURBINENISOLATION
1BSE001376 - GROUNDING CONCEPT INFORMATION
1BSE001377 - LONGITUDINAL SECTION
1BSE001713 - HYDR. AND LUBE OIL UNIT
1BSE501152 - Description of the Steam Turbine System
1BSE501157B - Starting & Operating Instruction of Steam Turbine
1BSE501163 - Description of the Steam Turbine Controller
HTGD691539V0001A - Flared Tube Fitting Triple-Lok
HTGD691702V0001C - 2 Way Flow Control Valve
HTGD691631V0002A - Water Injection Valve
HTGD691613V0002A - Vacuum Breaking Valve
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Blank Page
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MA - HTCT692560V9000 -
General Safety Rules
MA - HTCT692560V9000 -
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Revision History
Revision Content of Revision Total No. of
Pages in
Docu-
ment :
- - (16)
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MA - HTCT692560V9000 -
Contents
1 GENERAL
INFORMATION........................................................................
..........................................12
1.1 Use as
Designed...........................................................................
........................... 12
1.2 Identification of Residual Dangers and Dangerous
Areas ....................................... 12
1.3
Safety.............................................................................
.......................................... 13
1.4 Components and Spare
Parts..............................................................................
.... 13
1.5 Exclusions from
Liability..........................................................................
................. 13
2 INFORMATION FOR THE OPERATOR / OWNER OF THE
PLANT ..................................................15
2.1 Preparation of
Staff .............................................................................
..................... 15
2.2 Safety and Monitoring
Equipment..........................................................................
.. 15
2.3 Safety Rules that
Apply..............................................................................
.............. 15
2.4 Your
Responsibilities ..................................................................
............................. 16
2.5 Further Duties of the
Operator ..........................................................................
....... 17
3 INSTRUCTIONS FOR THE
SUPERVISOR.........................................................................
................17
3.1 Authorized
Operation .........................................................................
...................... 17
3.2 Following Existing Safety
Rules..............................................................................
. 17
3.3 Responsibilities of the
Supervisors .......................................................................
... 17
3.4 Manning the Operating
Stand .............................................................................
..... 18
4 INSTRUCTIONS FOR THE OPERATING AND MAINTENANCE
STAFF...........................................18
4.1 Working with Safety in

Mind...............................................................................
...... 18
4.2 Safe Condition for Maintenance
Work ..................................................................... 19
4.3 Safety Rules that
Apply..............................................................................
.............. 19
4.4 Questions concerning
Safety ............................................................................
....... 19
4.5 Conduct following
Malfunctions ......................................................................
......... 19
4.6 Emergency Shut-
down...............................................................................
.............. 19
4.7 Denial of Access to Unauthorized
Individuals.......................................................... 19
4.8 Reporting Damage and
Defects............................................................................
... 20
4.9 Special Tools and Spare
Parts .............................................................................
... 20
4.10 Special
Dangers............................................................................
........................... 20
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OPERATION & MAINTENANCE BOOK WP4110 &
WP4140
4.10.1 Shipment, Machine

Assembly..................................................................... 20
4.10.2 Initial Start-up after a Standstill for Maintenance
Work ............................... 20
4.10.3
Standstill.........................................................................
............................. 20
4.10.4 Protective
Covers.............................................................................
........... 20
4.10.5 Danger of
Fire ..............................................................................
............... 21
4.10.6
Noise .............................................................................
.............................. 21
4.10.7 Danger of
Explosions ........................................................................
.......... 21
4.10.8 Power Supply
System ............................................................................
..... 21
4.10.9 Lifting Equipment
Loads..............................................................................
21
4.10.10 Cleaning Agents and
Lubricants ................................................................. 21
4.10.11 Aggressive and Environmentally Harmful
Media ........................................ 21
4.10.12 Single-shaft Power Train
Arrangement ....................................................... 22
10 HTGD 693 000 V0140 A

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MA -
HTCT692560V9000 -
General
Safety Rules
This document comprises four sections:

1) General Information
2) Information for the operator / owner of the installation
3) Information for the plant supervisor
4) Information for the operating and maintenance staff.
The operating and maintenance staff must read Section 1 - "General
Information,"
and Section 4 - "Information for the Operating and Maintenance Staff."
The owner / operator and the supervisor must be familiar with the entire
document.
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1 GENERAL INFORMATION
1.1 Use as Designed

The following points must be noted to ensure that the machine (gas
turbine, steam
turbine, or generator) will be used as intended:
1. The operating instructions for the individual systems, blocks, and
components de-
fine their respective use as designed.
2. The machine must only be used within the permissible operating
ranges.
1.2 Identification of Residual Dangers and Dangerous Areas

Symbols in the operating instructions highlight special safety rules.
DANGER
DANGER - indicates an imminently hazardous situation which, if not
avoided,
will result in death or serious injury. This signal word is to be
limited to the
most extreme situation.
WARNING
WARNING - indicates a potentially hazardous situation which, if not
avoided,
could result in death or serious injury.
CAUTION
CAUTION - indicates a potentially hazardous situation which, if not
avoided,
may result in minor or moderate injury. It may also be used to alert
against
unsafe practices.
Caution
Information pointing out possible damages to the machine.
Note
Is an important element of the procedure and should be observed.
12
3 Illustrated parts list
Informs the user of the relevant Parts List where further details of
each com-
ponent can be found.
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MA -
HTCT692560V9000 -
General
Safety Rules
1.3 Safety
The plant has been designed according to state-of-the-art technology (at the
time of
its production) and complies with the generally recognized safety
regulations. All the
same, dangers may arise when operating the plant. To limit these dangers,
always
pay attention to all of the instructions in the operating instructions and to
all safety
rules.
WARNING
Hazardous operation
Operate the plant only when it is in a proper condition and always follow
the op-
erating instructions.
Operating safety is no longer guaranteed if the plant is used

inappropriately.
Here are some examples of inappropriate use:
a) Faulty maintenance work
b) Omission of tests and measurements that also serve to detect defects at an
early
stage
c) Non-compliance with maintenance intervals
d) Operation without the prescribed safety devices
e) Operation of the plant, blocks, or components in a manner other than as
de-
signed.
Note
Inappropriate use renders any and all liability on the part of the
manufacturer null
and void.
1.4 Components and Spare Parts

All plant components and accessories have been designed, selected, and
approved
by ALSTOM specially for this plant. This applies only if ALSTOM has made the
de-
livery and bears overall responsibility for it.
The installation or use of spare parts other than those approved by ALSTOM
can
change the characteristics of the plant and impair safety of operation.
1.5 Exclusions from Liability

ALSTOM excludes liability for any damage resulting from:
a) the use of parts not expressly approved and supplied by ALSTOM (This may
also
apply to parts included in the original delivery)
b) inappropriate handling of the plant or parts thereof during transport,
storage, as-
sembly, operation, maintenance, etc.
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c) force majeure (Acts of God) and normal wear

d) the intrusion of third parties
e) overstressing
f) inappropriate tools or operating materials
g) Extreme ambient temperatures
h) air pollution, relative humidity, radioactivity, fluctuations in voltage
and/or tem-
peratures
i) failure to comply with safety regulations
j) any change or modification to the safety equipment that has not expressly
been
approved beforehand in writing by ALSTOM
k) any other cause that does not fall within the responsibilities of ALSTOM.
14 HTGD 693 000 V0140 A

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MA -
HTCT692560V9000 -
General
Safety Rules
2 INFORMATION FOR THE OPERATOR / OWNER OF THE

PLANT
Inappropriate operation of the plant causes danger to man and machine, For
this
reason, the operating personnel must be trained in plant assembly, operation,
and
maintenance.
The dangers involved include, among others:
a) danger to life and limb of operating staff and other individuals
b) damage to the plant
c) environmental pollution
d) impairment of plant performance and function.
2.1 Preparation of Staff

Every individual whose assignments include assembly, operation, or
maintenance of
the machine must read, understand, and follow the relevant sections of these
in-
structions, "General Safety Rules." You must provide appropriate training for
this !
2.2 Safety and Monitoring Equipment

WARNING
Safety / Monitoring
Do not alter the installed safety and monitoring equipment!
2.3 Safety Rules that Apply

Make certain that your employees have access to local safety and accident
regula-
tions that apply at their workstation.
Here, for reference, are a few regulations that apply in Germany and in
Switzerland:
a) General Accident Prevention Regulations, VGB1
b) Noise Protection Regulations, VGB121
c) Regulations for Safety Marking at the Workplace, VGB125
d) Regulations for Electrical Plant and Equipment
e) Safety Rules for Generators per DIN 57105 Sheet 1, VDE0150 Part 1
f) Firefighting in the Area of Electrical Installations, VDE 0132
g) Further pertinent guidelines, e.g.,: VDE0100 / 0101 / 0107
h) Regulations covering Power Tools, VGB5 �2 Para. 1.
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2.4 Your Responsibilities

As the plant operator, you are responsible for operating it as designed and
according
to safety regulations.
Note
Do not make any compromise at the cost of safety !
Your employees must be able to act with safety in mind. To ensure this:
a) If there are not already alarm plans and rules of conduct existing for
cases of
emergency, prepare such plans and rules.
b) Instruct your employees to maintain the plant in a clean and manageable
condi-
tion and make certain that such instructions are followed.
c) Prepare company-internal safety and work procedures.
d) Appoint a safety director and make certain that he either has the
necessary know-
how or obtains it promptly.
e) Define responsibilities and authority. Unclear authority can detract from
safety.
f) Define which personnel must be at which workstation while the plant is in
opera-
tion.
g) Train your employees for their assignments.
h) Have your employees confirm in writing their receipt of the procedures and
their
participation in the training courses and drills.
i) Carefully drill your employees.
j) Your employees must have available to them personal safety gear (eye, ear,
body protectors, helmets, etc.).
k) Every employee must have read and understood the section that applies to
him
before starting to carry out any activities in the plant.
l) Only individuals who understand the language and content of the relevant
sec-
tions of the operating instructions may carry out work in the plant.
m) Every employee must have access to the operating instructions and, in
particular,
the safety rules. The operating staff are to be given access to the
following in-
structions:
1. For generators and all other electrical facilities:
� first aid following accidents involving electricity
� information sheet on fighting fires in electrical plants and their
vicinity.
2. For turbines:
� Instructions for First Aid in Case of Accidents, VDE0134 or ZH/403.
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MA -
HTCT692560V9000 -
General
Safety Rules
2.5 Further Duties of the Operator

Note
You alone, the operator, are responsible for fulfilling the inspection duties
(the ac-
ceptance report for safety).
Make sure that dangers in the workplace are identified with clear safety
markings in-
telligible at the plant location. Also make sure that zones to which no
access is per-
missible (e.g., during operation) are clearly identified. This also includes
identification
of noisy areas.
Note
The identification of danger zones frees you neither from observing the
applicable
safety rules and regulations, nor from checking to see that such rules are
being fol-
lowed by others.
Implement the safety measures described in the general rules and regulations
and in
the operating instructions.
3 INSTRUCTIONS FOR THE SUPERVISOR
3.1 Authorized Operation

The machine must be operated and maintained only by trained and authorized
oper-
ating staff.
The responsibilities of the staff for the various activities at the plant
must be defined
clearly.
Note
From the point of view of safety, no unclearly defined authority is
permissible. This
is particularly the case when working on electrical, control, hydraulic, and
pneu-
matic equipment. Such work must only be carried out by technical staff
trained
specifically for these activities and familiar as well with special local
governmental
provisions and requirements.
3.2 Following Existing Safety Rules

Always follow the applicable accident prevention and safety rules of the
country in-
volved when erecting, working on, and operating the plant.
3.3 Responsibilities of the Supervisors
a) Make sure that your fellow employees read and understand the pertinent
instruc-
tions in the operating instructions, particularly the information therein
that is rele-
vant to safety.
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17
b) Familiarize yourself with the operating instructions and the activities

relevant to
safety.
c) As supervisor, you are also responsible for removing any deficiencies
relevant to
safety. Instruct your employees to inform you immediately of any safety
deficien-
cies.
d) Explain to your employees the dangers involved with noise, fatigue, and
psycho-
logical stress.
e) Make sure that the intervals for maintenance and inspections are
maintained.
f) Check regularly the condition of your special tools and spare parts
yourself, or
make sure that your employees take over and perform this inspection work.
3.4 Manning the Operating Stand

Do not start the plant into operation until the prescribed staff trained to
operate the
plant is ready for work.
Prior to starting into operation, make sure that the alarm plans and other
documents
pertaining to safety are readily available.
4 INSTRUCTIONS FOR THE OPERATING AND MAINTENANCE

STAFF
4.1 Working with Safety in Mind

Pay particular attention to the following safety rules:
a) Help make your workplace safe ! Only carry out tasks that you are
authorized to
handle and for which you have read the operating instructions and
understood
them completely.
b) Follow the instructions of the safety director and his technical staff.
c) Use the safety equipment and wear the prescribed protective gear in the
danger-
ous working areas.
Note particularly:
a) Applicable safety and accident prevention procedures
b) Do not remove or disable safety devices (protective caps, etc.)
c) Follow "No smoking" rules
d) Do not carry out any work that may impair safety. For example:
� No work on or in systems that have not been disconnected (blocked)
� No work on systems under pressure
� No work on systems that are electrically live
e) Use the safety equipment
18 HTGD 693 000 V0140 A

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MA -
HTCT692560V9000 -
General
Safety Rules
f) Wear protective clothing where necessary or prescribed

g) Wear the prescribed ear protection where necessary
h) Remain at the workplace prescribed in the operating instructions while the
plant is
in operation.
4.2 Safe Condition for Maintenance Work

Only carry out work on the plant or on a system when it is in a non-operating
state
permissible for doing such work. Refer to the operating instructions for the
necessary
switch and equipment settings.
Secure sections of the plant that have been disconnected to prevent them from
start-
ing up accidentally. Remove the key from the key-operated switch, remove the
fuses, and post notices to warn against restarting the plant or section of
the plant.
4.3 Safety Rules that Apply

Pay attention to the applicable safety and accident prevention procedures
when
erecting, commissioning, operating, doing maintenance, and repairing the
machine.
4.4 Questions concerning Safety

Contact your safety director or supervisor immediately whenever you have any
ques-
tions concerning safety or detect dangers.
Your safety director or your superior will provide you with the safety
regulations that
apply for you.
4.5 Conduct following Malfunctions

Note the operating parameters and warning and malfunction reports and carry
out
the checking prescribed.
Note
React immediately to warning and malfunction reports and conduct yourself ac-
cording to the regulations, operating instructions, and alarm plans.
4.6 Emergency Shut-down

In case of obvious danger (fire, unusual noise, escaping steam, oil, or gas,
glowing,
etc.) use the manual emergency shut-off.
4.7 Denial of Access to Unauthorized Individuals

Only authorized individuals who are familiar with at least the minimum safety
rules
are granted access to the plant and the individual components thereof. Even
em-
ployees of the operator have no access unless explicitly authorized.
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4.8 Reporting Damage and Defects

Inspect the plant once per shift for damage visible externally.
Report immediately any changes that impair the safety or reliability of
the plant.
These also include unusual vibrations and sound.
4.9 Special Tools and Spare Parts

Keep the special tools and spare parts supplied by the manufacturer ready
for use.
Keep them clean and store them in a dry place. In addition, follow the
operating in-
structions for them.
4.10 Special Dangers

4.10.1 Shipment, Machine Assembly
Use only the fastening points, suspensions, and support and transport
equipment
detailed in the operating instructions.
This also applies for the disassembly and assembly done during maintenance
and
repair work.
4.10.2 Initial Start-up after a Standstill for Maintenance Work

Special rules apply here. It is not permissible to enter potentially
dangerous zones.
Note
These may also include zones which may be entered during normal operation.
Such initial start-ups must only be carried out by qualified staff who
must understand
the construction and operation of the plant, and follow the operating
instructions.
4.10.3 Standstill
Take the precautions customary locally with regard to preventing the
escape of com-
bustible or poisonous gas.
Escaping gas presents the risk of an explosion when doing welding (gas
leakage).
WARNING
Risk of poisoning / Risk of explosion
It is not permissible to enter the machine if gas or steam is escaping.
4.10.4 Protective Covers

Regularly check the protective covers on rotating machine parts to make
sure they fit
correctly and are secure.
20 HTGD 693 000 V0140 A

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MA -
HTCT692560V9000 -
General
Safety Rules
If you have removed the protective covers for maintenance or repair work,
secure
them in place again with the locking elements provided for this purpose
before you
recommmission the machine. Only then has the work been completed.
4.10.5 Danger of Fire

Keep inflammable materials away from the turbine. It is not permissible
to store in-
flammable materials near the turbine. Be particularly careful to keep
liquid media of
any kind away from the insulation on the generators and the turbines.
4.10.6 Noise
Wear ear protectors in the designated noise zones.
4.10.7 Danger of Explosions

Note the explosion danger zones. In these zones, in accordance with the
explosion
protection documents, safety procedures (conduct, access, marking) and
restrictions
(tools, clothing, structural modifications) must be observed.
4.10.8 Power Supply System

No work is permitted on the DC power supply and the uninterruptible power
supply
(UPS) while the machine is running.
4.10.9 Lifting Equipment Loads

When using lifting gear, cranes, etc., make sure that such equipment is
not over-
loaded. Refer to the operating instructions for the weights of the
individual machine
parts.
4.10.10 Cleaning Agents and Lubricants

Use only the cleaning agents or lubricants specified or recommended by
ALSTOM.
ALSTOM has tested the characteristics of these materials.
Note
The use of non-recommended materials may cause damage to the plant and to
the
environment.
4.10.11 Aggressive and Environmentally Harmful Media

Follow all safety regulations when handling these media and observe the
regulations
covering their disposal.
en HTGD 693 000 V0140 A
21
4.10.12 Single-shaft Power Train Arrangement
DANGER
Hazardous operation
Turning the gas turbine rotor manually while the steam turbine is
operated on turn-
ing gear is considered as a potential health and safety issue. Engagement
of the
SSS clutch cannot be excluded when the gas turbine speed is below the
steam
turbine speed while the steam turbine turning gear is in operation.
In order to perform any maintenance work on the GT, the steam turbine
turning
gear motor must be either stationary or running at stable speed. As long
as the
steam turbine turning gear is in operation, the following recommendations
have to
be observed when working on the gas turbine or generator:
� If the locking device on the SSS clutch is not engaged, hands-on work
on rotat-
ing parts or on static parts in close vicinity to rotating components
is forbidden
� In order to perform hands-on work on rotating parts, or on static
parts in close
vicinity to rotating parts, the locking device on the SSS clutch must
be engaged.
� Turning of the gas turbine I generator rotor shall be performed as
required us-
ing rotor barring or hand operation of the rotor barring pump. For
this the lock-
ing device on the clutch needs to be removed and reengaged again
afterwards
before hands-on work is continued.
Note
The steam turbine turning gear can be switched off if the metal
temperature on the
steam turbine is below the temperature defined in the Operation and
Maintenance
Manual.
Note
Before the steam turbine turning gear can be switched on or off it must
be con-
firmed that no person is in range of the rotating parts of the gas
turbine I generator.
End of General Safety Rules
HTCT692560V9000
22 HTGD 693 000 V0140 A
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MA - HTGD693028V9005 -
Introduction to the
Steam Turbine Plant
Multi-shaft unit in a
MA - HTGD693028V9005 -
Introduction to the
Steam Turbine Plant
combined cycle power station
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Revision History
Revision Content of Change Document Pages
total :
- - (8)
24 HTGD 693 000 V0140 A en

MA - HTGD693028V9005 -
Introduction to the
Steam Turbine Plant
Contents
1
CONCEPT............................................................................
................................................................27
2 WATER STEAM
CYCLE..............................................................................
........................................28
3 MAIN DESIGN GROUPS OF THE STEAM
TURBINE ........................................................................29
3.1 HP
turbine ...........................................................................
..................................... 29
3.2 LP
turbine............................................................................
..................................... 29
3.3 Gland steam
condenser..........................................................................
................. 29
3.4 Lubrication and Control Oil
Tank .............................................................................
29
4 Data
Sheet .............................................................................
..............................................................30
en HTGD 693 000 V0140 A

25
OPERATION & MAINTENANCE BOOK WP4110
& WP4140
Figures
Fig. 1 Layout of the steam turbine

unit ..............................................................................
.......... 27
Technical description of the feed water tank
Technical description of the steam turbine
Technical description of the gland steam condenser
References
Description of the steam turbine systems
Description of the gland steam system
26 HTGD 693 000 V0140 A

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MA -
HTGD693028V9005 -
Introduction to the
Steam
Turbine Plant
Multi-shaft
unit in a
5 CONCEPT
The steam turbine is designed to be used in a combined cycle plant together
with a
gas turbine. The mass flow from the heat recovery steam generator (HRSG)
supplies
a steam turbine, comprising a high pressure (HP) and a low pressure (LP) flow.
The layout of the steam turbine permits favourable machine house dimensions,
see
Fig. 1.
The lube oil / hydraulic oil system for this unit is combined with most of the
compo-
nents located on the lubrication oil tank and covers the demand of the
complete shaft
train, consisting of generator and steam turbine.
1 2 3
4
CHEE0109_
6 5
A3182_
Pos Designation Pos Designation

1 Generator 4 Condenser neck
2 High pressure turbine 5 Live steam admission valves
3 Low pressure turbine 6 Secondary steam
Fig. 1 Layout of the steam turbine unit
en HTGD 693 000 V0140 A

27
6 WATER STEAM CYCLE

The live steam passes from the HRSG through a live steam valve, which
comprises
a stop valve and a control valve, into the HP inner casing where it expands in
the
blading.
The direction of the expanded steam is reversed in the HP turbine exhaust, the
steam then flows to the LP turbine, located in the same casing.
This reversal of direction provides axial thrust balance in the combined HP/LP
tur-
bine.
The LP steam, that is also generated by the HRSG, flows as secondary steam
through an inlet pipe and a low pressure valve, consisting of a butterfly stop
and a
butterfly control valve, into the HP outer casing.
The already partially expanded steam from the HP turbine continues to expand
to-
gether with the admitted LP steam in the LP turbine blades. The steam then
flows to
the main condenser after expansion has been completed.
After condensation the condensate is pumped to the feed water tank to be
reheated
and then passed to the HRSG.
The gland steam leak-off system, which is connected to the outer chambers of
the
steam turbine shaft seals and the valve spindle seals, is routed to the gland
steam
condenser. A fan, mounted on the gland steam condenser, keeps the system pres-
sure slightly below the atmospheric pressure.
Air and steam are separated in the gland steam condenser. The air is led to
atmos-
phere, the steam condenses and is returned to the water steam cycle.
28 HTGD 693 000 V0140 A

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MA - HTGD693028V9005
-
Introduction
to the
Steam Turbine
Plant
Multi-shaft
unit in a
7 MAIN DESIGN GROUPS OF THE STEAM TURBINE
7.1 HP turbine
The single-flow HP turbine consists of a cast outer casing, a cast and bladed
inner
casing with balance piston and steam inlet part and a shaft seal. The HP and
the LP
turbine have a common bladed rotor.
The outer casing has a cross flange for flange-mounting the LP outer casing;
the HP
inner casing is arranged in reverse flow, compared with that of the LP
turbine.
The steam valve housing is flanged to the outer casing; the secondary steam
is led
directly into the outer casing through an inlet pipe.
7.2 LP turbine
The single-flow LP turbine with axial exhaust consists of a welded outer
casing, a
cast and bladed blade carrier, hook-mounted in the outer casing, a shaft seal
and an
exhaust collar.
The outer casing has a cross flange for flange-mounting to the HP turbine.
The LP turbine exhaust collar is connected by a flexible compensator to the
ducting
which leads to the condenser.
7.3 Gland steam condenser

The gland steam condenser is a weldment with straight and condensate-cooled
cool-
ing tubes, inserted in tubesheets, integral hotwell and water boxes. A fan
sucks the
steam-air mixture from the shaft seal systems of the steam turbine, condenses
the
steam and evacuates the air to the atmosphere.
7.4 Lubrication and Control Oil Tank

All components like filters and coolers and the pumps for the lube, jacking
and hy-
draulic oil supplies and the associated control and safety equipment of the
steam
turbine are mounted on or attached to the lubrication oil tank. The
lubricating and
pressure media are distributed through pipes that are separate for each
system.
en HTGD 693 000 V0140 A
29
8 DATA SHEET
Name of plant : Muara Tawar 5
ALSTOM-Order-No : 30-0140
Type of machine : VLB -MDG100K/1 - NE33AA
Type of plant : KA13E2 - DKZ1-1N33AA
Technical data of the steam turbine

Load 100% MAX MIN
Ouput MW 81 86.4
Speed 1/min 3000
Live steam pressure bar 66.24 70.0 33.0
Live steam temperature �C 508.3 520.0
Second steam admission pres- bar 6.0 6.26 4.2
sure
Second steam temperature �C 265.7 266.2
Condenser pressure bar 0.075 0.087
HTGD693028V9005
30 HTGD 693 000 V0140 A en

MA - HTGD693027V9005 -
Technical Description
of the Steam Turbine
MA - HTGD693027V9005 -
en HTGD 693 000 V0140 A 31

Revision History
total :
- - (44)
32 HTGD 693 000 V0140 A en

MA - HTGD693027V9005 -
Contents
1
GENERAL ...........................................................................
.................................................................37
1.1
Foundation ........................................................................
....................................... 37
1.2 Rotor
line...............................................................................
................................... 37
1.3 Expansion and
fixation...........................................................................
.................. 37
2
COUPLINGS .........................................................................
...............................................................38
2.1 Expansion sleeve

coupling ..........................................................................
............ 38
3 HIGH PRESSURE/LOW PRESSURE
TURBINE ...........................................................................
.....39
3.1 HP
turbine ...........................................................................
..................................... 40
3.1.1 Outer
casing ............................................................................
.................... 40
3.1.2 Inner
casing.............................................................................
.................... 41
3.1.3 Shaft
seal ..............................................................................
...................... 41
3.1.4 Turbine
rotor..............................................................................
.................. 42
3.1.5
Blading ...........................................................................
............................. 42
3.2 LP
turbine............................................................................
..................................... 43
3.2.1 Outer
casing ............................................................................
.................... 44
3.2.2 Water
injection..........................................................................
................... 44
3.2.3 Rupture
diaphragm..........................................................................
............ 44
3.2.4 Vacuum breaking
valve .............................................................................
.. 44
3.2.5 LP blade
carrier ...........................................................................
................ 44
3.2.6 Shaft
seal ..............................................................................
...................... 45
3.2.7
Blading ...........................................................................
............................. 45
4 LIVE STEAM
VALVES ............................................................................
.............................................46
4.1 Live steam stop

valve .............................................................................
................. 48
4.1.1 Live steam stop valve
actuator.................................................................... 49
4.1.2 Stroke
tests .............................................................................
.................... 50
4.2 Live steam control
valve .............................................................................
............. 50
4.2.1 Live steam control valve
actuator................................................................ 51
4.2.2 Stroke
tests .............................................................................
.................... 52
5 SECONDARY STEAM
VALVES ............................................................................
..............................53
5.1 Secondary steam stop

valve..............................................................................
...... 54
5.1.1 Stop valve
actuator...........................................................................
........... 54
5.1.2 Pilot control
system ............................................................................
......... 54
5.1.3 Stroke
test ..............................................................................
..................... 54
5.2 Secondary steam control
valve..............................................................................
.. 54
en HTGD 693 000 V0140 A
33
WP4110 & WP4140
5.2.1 Control valve

actuator ..........................................................................
....... 55
5.2.2 Pilot control
system ............................................................................
......... 55
5.2.3 Stroke
test ..............................................................................
..................... 55
5.3 Steam
strainer ..........................................................................
............................... 55
6 BEARING
PEDESTALS .........................................................................
............................................. 56
6.1 Front bearing

pedestal...........................................................................
.................. 56
6.1.1 Combined thrust and journal
bearing .......................................................... 58
6.2 Low pressure bearing
casing.............................................................................
...... 60
6.2.1 Pocket-type journal
bearing ........................................................................ 62
7 ROTOR TURNING
GEAR ..............................................................................
..................................... 64
7.1
General ...........................................................................
......................................... 64
7.2
Tasks .............................................................................
.......................................... 64
7.3
Design.............................................................................
......................................... 65
8 TURBINE
INSULATION ........................................................................
.............................................. 65
9 TURBINE
INSTRUMENTS........................................................................
.......................................... 66
9.1 Temperature sensors at

turbines...........................................................................
.. 66
9.1.1 Startup
probes.............................................................................
................ 66
9.1.2
Thermocouples .....................................................................
...................... 66
9.2 Bearing temperature
measurement .......................................................................
.. 66
9.3 Speed
sensor.............................................................................
.............................. 67
9.4 Vibration pick-
up ................................................................................
...................... 67
9.5 Expansion
transmitter .......................................................................
....................... 67
9.5.1 Differential expansion
transmitter................................................................ 67
9.5.2 Absolute expansion
transmitter................................................................... 67
9.5.3 Shaft position
monitor ...........................................................................
...... 67
9.6 Pressure
transmitter .......................................................................
......................... 68
10 EXPLANATORY
DESIGNATIONS.......................................................................
............................... 69
10.1 Turbine
subassemblies......................................................................
...................... 69
10.2 Designation of the external
connections.................................................................. 69
10.3 Designation of code
letters ...........................................................................
........... 69
34 HTGD 693 000 V0140 A

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MA - HTGD693027V9005 -
Figures
Fig. 2-1 Expansion sleeve

coupling ..........................................................................
................... 38
Fig. 3-1 HP/LP
turbine ...........................................................................
...................................... 39
Fig. 3-2 HP
turbine............................................................................
........................................... 40
Fig. 3-3 LP
turbine ...........................................................................
............................................ 43
Fig. 4-1 Live steam valve
housing ...........................................................................
.................... 46
Fig. 4-2 Swing arm
support............................................................................
.............................. 47
Fig. 4-3 Live steam stop
valve .............................................................................
........................ 48
Fig. 4-4 Live steam stop valve
actuator ..........................................................................
............. 49
Fig. 4-5 Live steam control
valve .............................................................................
.................... 50
Fig. 4-6 Live steam control valve
actuator ..........................................................................
......... 51
Fig. 5-1 LP steam
valve .............................................................................
.................................. 53
Fig. 6-1 Front bearing
pedestal...........................................................................
........................ 57
Fig. 6-2 Combined thrust and journal
bearing ...........................................................................
. 59
Fig. 6-3 LP bearing
casing.............................................................................
.............................. 61
Fig. 6-4 Pocket-type journal
bearing............................................................................
................ 63
Fig. 7-1 Rotor turning
gear...............................................................................
............................ 64
Fig. 10-1 Turbine
views .............................................................................
.................................. 71
en HTGD 693 000 V0140 A

35
36 HTGD 693 000 V0140 A en

MA -
HTGD693027V9005 -
Technical
Description
of the Steam
Turbine
1 GENERAL
1.1 Foundation
The foundation considerably influences the running smoothness of a turboset.
When
determining the foundation components which largely define the natural
frequency of
the foundation, ALSTOM selects the design that is most advantageous for the
oper-
ating behaviour of the turboset.
A simple, operationally reliable and cost-effective configuration of the
foundation is
therefore already taken into account when designing a turboset.
1.2 Rotor line

The various steam turbine rotors are coupled in such a way that they are
without
bending moments in operation. They are supported via a journal bearing on a
bear-
ing pedestal, located between the different subassemblies. This single-
bearing con-
cept ensures clear bearing loads, even in the case of foundation
deformations.
The rigid cast design of the bearing pedestals positively influences the
running
smoothness and operational reliability of the turboset. For design reasons
the bear-
ing casing in the LP exhaust is a weldment.
1.3 Expansion and fixation

The steam turbine train is fixed axially by a two-collar thrust bearing in
the thrust
bearing pedestal. The relative and absolute fixed points of the turbine are
at the LP
exhaust casing.
To permit thermal expansion of the turbine casings the free-standing bearing
pedes-
tals can slide in axial direction. The turbine casings expand and shift
jointly with the
thrust bearing pedestal towards the generator.
This expansion concept has the advantage of minimised differential expansion
be-
tween stationary and rotating turbine components, resulting in a higher
efficiency due
to small seal clearances
en HTGD 693 000 V0140 A

37
2 COUPLINGS
2.1 Expansion sleeve coupling

The expansion sleeve coupling is easy to assemble and maintain and connects
rigid
and positively the HP / LP turbines to the generator.
The conical coupling bolts and expansion sleeves are inserted in the honed
bores of
the coupling flanges. The coupling bolts are tightened hydraulically so that
the ex-
pansion sleeves expand elastically and compensate the assembly clearances.

1 Coupling halves 2 Coupling bolt
3 Expansion sleeve 4 Coupling nut
5 Locking ring
Fig. 2-1 Expansion sleeve coupling
The torque is transmitted in operation by the shear stress of the coupling

bolts and
expansion sleeves.
The coupling faces cannot move even if there are sudden changes in the rotor
line
loads. This means that the coupling bolts and expansion sleeves can be
removed
when necessary without causing damage to the coupling flanges.
38 HTGD 693 000 V0140 A

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MA - HTGD693027V9005
-
Technical
Description
of the Steam
Turbine
To reduce aerodynamic losses the nuts of the coupling bolts fit in recesses in
the
coupling flanges. The centring spigot and recess of the coupling flanges serve
as an
assembly aid.
3 HIGH PRESSURE/LOW PRESSURE TURBINE

The main components of the combined HP and LP turbine, both of the single-flow
type, are the outer casing, the bladed HP inner casing, with reverse flow
compared
to the LP turbine and with an integral balance piston and inlet part, the
hook-
mounted LP stationary blade carrier, the common turbine rotor and the bearing
cas-
ing, installed in the LP exhaust casing.
1 2 3
CGCA0203_
A2453_

1 HP turbine 3 LP bearing casing
2 LP turbine
Fig. 3-1 HP/LP turbine
en HTGD 693 000 V0140 A

39
3.1 HP turbine
The distribution of the pressure and temperature gradients to two casings
ensures
wall thicknesses and flange geometries that are favourable in terms of
casting prac-
tice and loading.
The internals, especially the blading, can be inspected with an endoscope
through
openings, provided by the design, without requiring dismantling of the
casings.
3 10 2 5 1 4 8
6 9 7
CGCA0204_
A2454_

1 Outer casing 6 Secondary steam
supply
2 Inner casing 7 Startup probe
3 Shaft seal 8 Intermediate piston
4 Turbine rotor 9 Inlet part
5 Blading 10 Balance piston
Fig. 3-2 HP turbine
3.1.1 Outer casing

The cylindrical outer casing is split horizontally along the turbine axis
and held to-
gether by hydraulically tightened elongation studs. The flanges are
equipped with
sealing and support strips to ensure optimum sealing.
The steam flows from the HRSG through a flanged-on valve housing with
integral dif-
fuser to the inner casing inlet part. The inlet pipe for the secondary
steam supply and
40 HTGD 693 000 V0140 A

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MA -
HTGD693027V9005 -
Technical
Description
of the
Steam Turbine
the gland steam and leak-off connections for the shaft seals are located at
the casing
lower half.
Claws with integral adjusting elements and cast on to the outer casing
support the
outer casing on the bearing pedestal at the thrust bearing end. Adjustable
fixing ele-
ments connect the casing axially with the bearing pedestal.
A machined vertical flange with elongation studs is provided at the inlet-
side end for
mounting the LP outer casing.
3.1.2 Inner casing

The conical inner casing is split along the turbine axis and held together
by hydrauli-
cally tightened elongation studs. The steam inlet part is designed as a
360� scroll.
The inner casing houses the stationary blades and the sealing strips,
mounted in ra-
dial grooves. The first stationary blade row is located in the inlet
scrolls to ensure
uniform steam distribution.
Due to the reverse flow design of the HP/LP turbine, the axial thrusts in
the turbine
are almost balanced. The single-stage balance piston is a labyrinth seal
and com-
pensates the residual thrust. The sealing elements yield radially to
prevent danger-
ous rubbing, the sealing strips are caulked in the rotor.
In the steam exhaust region at the level of the horizontal joint the inner
casing is
fixed axially and supported radially by adjustable keys. In the steam inlet
region the
inner casing is supported radially at the level of the horizontal joint by
adjustable slid-
ing pieces.
Sliding keys, mounted at the top and bottom, provide lateral guiding of the
inner cas-
ing in the outer casing in the steam inlet region. A lateral key, installed
in the outer
casing lower half, guides the inner casing in the steam exhaust region.
After expanding in the blading of the HP turbine, the steam flows together
with the
secondary steam in the opposite direction to the LP turbine.
3.1.3 Shaft seal

The shaft seal, designed as a labyrinth seal, seals the turbine outer
casing which is
under steam pressure, against the atmosphere at the rotor penetrations and
pre-
vents the steam escaping from the turbine.
The sealing elements yield radially to prevent dangerous rubbing, the
sealing strips
are caulked in the rotor. The shaft seal housing and the turbine outer
casing form
annular ducts for the gland steam and leak-off systems.
The gland steam system is operated with slight gauge pressure; the leak-off
system,
having a slight vacuum, is routed with the sucked-in air to the gland steam
con-
denser.
en HTGD 693 000 V0140 A

41
3.1.4 Turbine rotor

The common turbine rotor of the HP and the LP turbine is welded from shaft
disks
and shaft ends in accordance with a proven ALSTOM practice. The rotating
blades
are mounted in radial grooves.
Sealing strips, inserted in grooves and fastened with caulking wire, and
their alter-
nate arrangement minimise the gap losses. This ensures optimum utilisation
of the
steam and a high efficiency.
The rotor ends are provided with balancing holes that are distributed
radially and
permit rebalancing with closed casings. The coupling flange and the bearing
journal
are integral parts of the rotor.
3.1.5 Blading
The stationary and rotating blades are each milled from one piece so that
blade root,
airfoil and shroud form a homogeneous unit. This robust design is therefore
easy to
assemble.
The milled, rhombic rotating blades have shrouds that have a slight
oversize com-
pared with the blade root. When assembled in rows, the rhombic shrouds are
pressed against one another so strongly that the airfoils twist
elastically.
The resultant torsional prestress ensures adequate shroud pressure under
all oper-
ating conditions and a stable, closed shroud ring.
The shroud ring which has no gaps or clearance provides a stiffness that
makes the
blades insensitive to resonance with low excitation frequencies.
42 HTGD 693 000 V0140 A

en
MA -
HTGD693027V9005 -
Technical
Description
of the
Steam Turbine
3.2 LP turbine
As a result of the single casing design of the HP/LP turbine the temperature
gradient
is distributed from the hot HP turbine to the significantly colder LP turbine
so that dif-
ferent materials are used.

1 Outer casing 5 Blade carrier
2 Water injection 6 Shaft seal
3 Rupture diaphragm 7 Blading
4 Turbine rotor
Fig. 3-3 LP turbine
The internals, especially the blading, can be inspected with an endoscope

through
openings, provided by the design, without requiring dismantling of the
casings.
en HTGD 693 000 V0140 A

43
3.2.1 Outer casing

The LP outer casing is a solid weldment with integral vertical flange that
is bolted to
the HP turbine.
The axially arranged exhaust collar is connected with the axially arranged
condenser
ducting by an elastic sleeve that compensates for the thermal movements of
the
outer casing. An adjustment device permits alignment of the sleeve with the
con-
denser duct neck and fixes axially the connection of turbine and condenser
duct.
The casing is supported by lateral support strips via adjustable supports
on the foun-
dation and secured directly on the foundation by foundation bolts. The
supports, pro-
vided with sliding elements, permit the outer casing to expand
unrestrictedly from its
absolute fixed point, arranged laterally at the supports.
3.2.2 Water injection

A water injection system, to be supplied if necessary via a water injection
valve, pro-
vides cooling during no-load and low-load operation. Its supply depends on
the
steam mass flow in the turbine. The water injection system protects against
over-
heating due to ventilation of the LP end stage and consists of pipes,
installed in the
exhaust casing, with inserted water spray nozzles.
3.2.3 Rupture diaphragm

A rupture diaphragm is mounted on the outer casing upper half to protect
the con-
denser and prevent overpressure in the turbine. The rupture diaphragm
consists
mainly of a special lead plate and is a planned weak point that will burst
at a defined
pressure in the case of inadmissible operating conditions. In normal
operation the
lead plates lies steam-tight on the vacuum supports of the rupture
diaphragms.
3.2.4 Vacuum breaking valve

A vacuum breaking valve is attached to the LP outer casing to permit quick
passing
of the critical speed ranges during turbine rundown. In certain speed
ranges the con-
denser vacuum must be broken partially or completely in order to achieve
certain
condenser pressures.
Under certain operating conditions a full vacuum break is not permitted, in
order to
protect, for example, the LP last-stage blades.
3.2.5 LP blade carrier

The blade carrier houses the stationary blades and the related sealing
strips,
mounted in radial grooves. The blade carrier is split horizontally along
the turbine
axis and held together by hydraulically tightened elongation studs.
Adjusting elements that can be adjusted in height and are mounted below the
parting
plane support the blade carrier. In axial direction the blade carrier is
fixed in the LP
outer casing in a groove. Adjustable guide bolts, mounted in the outer
casing lower
half, provide radial guiding.
44 HTGD 693 000 V0140 A

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MA -
HTGD693027V9005 -
Technical
Description
of the
Steam Turbine
All support and fixing systems are so designed and located that the outer
casing and
blade carrier can expand freely in all directions without the position of
their centre
axes being changed.
3.2.6 Shaft seal

The shaft seal shall seal the exhaust chamber, being under vacuum, against
the
bearing casing cowling at the rotor penetration. The adjustable fixing
system, bolted
to the bearing casing cowling, permits minimum labyrinth clearances so that
only a
small quantity of gland steam is required.
This arrangement permits thermal movements of the outer casing relative to
the
shaft seal housing without influencing the seal ring clearances. The
sealing elements
yield radially to prevent dangerous rubbing. The shaft seal housing
contains annular
ducts for connection to the gland steam and leak-off system each.
The gland steam system is operated with slight gauge pressure; the leak-off
system,
having a slight vacuum, is routed with the sucked-in air to the gland steam
con-
denser.
3.2.7 Blading
The stationary and rotating blades of the first rows are each milled from
one piece so
that blade root, airfoil and shroud form a homogeneous unit. This robust
design is
therefore easy to assemble.
The milled, rhombic rotating blades have a shroud that has a slight
oversize com-
pared with the blade root. When assembled in rows, the rhombic shrouds are
strongly pressed against one another so strongly that the airfoils twist
elastically.
The resultant torsional prestress ensures adequate shroud pressure under
all oper-
ating conditions and a stable, closed shroud ring.
The shroud ring which has no gaps or clearance provides a stiffness that
makes the
blades insensitive to resonance with low excitation frequencies.
The blades of the last two rows are also made from one piece, but their
size requires
a different manufacturing procedure. The stationary blades are ferro
castings, the ro-
tating blades are of forged alloy steel. The airfoils are tapered towards
the end to re-
duce the stresses in the blade. The twisted shape of the airfoil ensures
adaptation to
the flow conditions.
en HTGD 693 000 V0140 A

45
4 LIVE STEAM VALVES

The live steam passes through the live steam pipe into the valve housing,
flanged to
the HP turbine and comprising a stop and a control valve with actuator. Acting
as a
safety valve, the stop valve is located upstream of the control valve, looking
in direc-
tion of the flow.
Connection with the turbine casing is below the horizontal casing joint so
that the as-
sembly work when opening the HP turbine is reduced.

1 Stop valve actuator 4 Control valve
2 Stop valve 5 Swing arm support
3 Control valve actuator 6 Valve housing
Fig. 4-1 Live steam valve housing
Due to its size, overhang and weight, the valve housing is supported on the
founda-
tion by a double-hinged, thermally flexible swing arm support. The valve
weight is
accommodated by laminated Belleville springs.
46 HTGD 693 000 V0140 A

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MA - HTGD693027V9005 -

1 Belleville springs
Fig. 4-2 Swing arm support
en HTGD 693 000 V0140 A 47

4.1 Live steam stop valve

The stop valve is a balanced single-seat valve with pilot stroke. Its steam
strainer
protects the internals of valve and turbine against damage due to solid
particles. The
valve seat is bolted in the valve housing which is provided with a leak-off
connection.
4 3 2 1
CVAB0201_

1 Valve seat 3 Lock
2 Steam strainer 4 Sealing element
Fig. 4-3 Live steam stop valve
The stop valve can assume two stationary positions, fully open or fully
closed. The
pilot stroke of the stop valve initiates the opening movement. If the valve
is open, the
valve head is pressed against the backseat in the lock. The valve is then
insensitive
to vibration excitation and sealed towards the outside.
The closing movement is also initiated by the pilot stroke.
With a closed valve, the spindle leakage is minimised by a multi-part sealing
ele-
ment.
48 HTGD 693 000 V0140 A

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MA -
HTGD693027V9005 -
Technical
Description
of the
Steam Turbine
4.1.1 Live steam stop valve actuator

The stop valve actuator is a hydraulic actuator for directly actuating the
stop valve. In
the case of inadmissible operating conditions or a shutdown the actuator
and the
coupled valve shuts off the steam supply to the turbine. The actuator
operates ac-
cording to the "fail-safe" principle, i.e. the actuator closes the stop
valve with spring
force when there is a pressure drop in the safety system.

1 Actuator piston 2 Discharge amplifier
Fig. 4-4 Live steam stop valve actuator
The main parts of the actuator are the housing, the actuator piston with
Belleville
spring assembly, the discharge amplifier and the control elements for the
stroke test.
Inductive proximity switches indicate the open or closed position of the
stop valve.
To open the valve, pressure is built up in the safety system and pressure
fluid flows
via a check valve and an orifice in the valve plate of the discharge
amplifier into the
space below the actuator piston. With increasing pressure the Belleville
spring as-
sembly is compressed, the actuator piston and the valve move in an opening
direc-
tion. The stroke of the coupled valve limits the end position.
The closing movement is initiated by the pressure collapse in the safety
system. The
pressure before the valve plate of the discharge amplifier drops.
The backpressure generated by the Belleville spring assembly opens the
valve plate.
The stroke volume of the actuator piston is directly discharged into the
drain via
bores in the valve body. As a consequence, the stop valve closes.
en HTGD 693 000 V0140 A

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4.1.2 Stroke tests

The stop valve must be subjected periodically to a stroke test in normal
operation.
The steam supply to the turbine must, however, be ensured. The stroke test
must
also be compatible with the operating concept of the turbine.
4.2 Live steam control valve

The control valve controls the steam flow rate to the HP turbine and blocks
the
steam supply, together with the stop valve, in the case of a disturbance.
The valve is
a balanced single-seat valve with a flow equaliser; its diffuser leads
directly into the
HP inner casing where it is sealed off with a thermally flexible steam seal
ring.
2 3
1
CVAC0201_

1 Diffuser 3 Piston rings
2 Sealing element
Fig. 4-5 Live steam control valve
The control valve can assume any position between fully open and closed.
The opening movement of the control valve is initiated with an open stop
valve. A
multi-part sealing element seals the spindle towards the atmosphere.
Piston rings are inserted in the guiding section between the lock and the
valve body
and ensure the required steam tightness when the valve is closed.
50 HTGD 693 000 V0140 A

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MA -
HTGD693027V9005 -
Technical
Description
of the
Steam Turbine
4.2.1 Live steam control valve actuator

The control valve actuator is a hydraulic actuator with end position
dampening for di-
rectly actuating the control valve. It can assume any position as a
stationary position
over the entire stroke range. The actuator operates according to the "fail-
safe" prin-
ciple, i.e. the actuator closes the valve with spring force when there is a
pressure
drop in the safety system.
In the case of inadmissible operating conditions or a shutdown the actuator
and the
coupled valve shut off the steam supply to the turbine.

1 Actuator piston 3 Discharge amplifier
2 Proportional valve 4 Stroke transmitter
Fig. 4-6 Live steam control valve actuator
The main parts of the actuator are the housing, the actuator piston with
Belleville
spring assembly, a proportional valve with power amplifier, the discharge
amplifier
and a position feedback.
The pilot control system, comprising of, a discharge amplifier, and a
proportional
valve with power amplifier and integral stroke transmitter, is flanged
directly to the
actuator. Via the pressure below the actuator piston the proportional valve
controls
the position of the actuator in accordance with the electrical input signal
which also
corresponds with the control valve position, required by the turbine
controller. This
control can be configured at the power amplifier.
When the valve opens, pressure fluid flows from the proportional valve into
the
space below the actuator piston via orifices in the valve plate of the
discharge ampli-
en HTGD 693 000 V0140 A

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fier. The orifices limit the maximum opening speed; the valve plate of the
discharge
amplifier remains always closed.
The control mode and control variables can be set at the power amplifier
and are
preadjusted for optimum operation. The stroke transmitter of the actuator
is installed
in a chamber that is not oil-wetted, which transmits both the position
signal of the
control valve actuator, and the control valve, to the turbine controller.
The closing movement is initiated by the pressure collapse in the safety
system. The
pressure before the valve plate of the discharge amplifier drops.
The backpressure generated by the Belleville spring assembly opens the
valve plate.
The stroke volume of the actuator piston is directly discharged to the
drain via bores
in the valve body. As a consequence, the control valve closes.
4.2.2 Stroke tests

The control valve must be subjected periodically to a stroke test in normal
operation.
must
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MA -
HTGD693027V9005 -
Technical
Description
of the Steam
Turbine
5 SECONDARY STEAM VALVES

The LP steam flows through a steam pipe to the LP valve and then through an
inlet
pipe to the exhaust end of the HP turbine, from where the LP turbine is fed.
The valve consists of the following subassemblies, arranged one behind the
other in
direction of the flow: stop valve with actuator and control elements, control
valve with
actuator and control elements and a steam strainer.

1 Sec. steam stop valve 4 Sec. steam control valve
act.
2 Sec. steam stop valve actuator 5 Steam strainer
3 Sec. steam control valve
Fig. 5-1 LP steam valve
The stop valve and the control valve are identical, double-eccentrically
supported
and unilaterally sealing butterfly valves. The steam force acts on the valve
disk in
any position in closing direction due to the eccentric arrangement. The closed
posi-
tion of the valves is defined by a stop in the actuator. For safety reasons,
additional
stops are provided for the valve disk in the valve housing.
The valve disk is sealed in the closed position by metallic seals into which
the cone-
shaped valve disk edges penetrate during closing. The disk edges are hard-
faced.
en HTGD 693 000 V0140 A

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Due to its size, overhang and weight, the valve housing is supported on the
founda-
tion by an adjustable, thermally flexible swing arm support.
5.1 Secondary steam stop valve

The stop valve is a butterfly valve that is controlled by the turbine
safety system and
can assume two positions, fully open or closed. In the case of inadmissible
operating
conditions or a shutdown the valve shuts off the steam supply to the LP
turbine.
The main parts of the valve are the housing with integral valve seat, the
eccentrically
supported valve disk, the actuator with pilot control and the proximity
switches for
position indication.
5.1.1 Stop valve actuator

The stop valve actuator is a hydraulic actuator with end position dampening
for di-
rectly actuating the stop valve. In the case of inadmissible operating
conditions or a
shutdown the actuator and the coupled valve shut off the steam supply to
the tur-
bine. The actuator operates according to the "fail-safe" principle, i.e.
the actuator
closes the stop valve with spring force in the case of a pressure drop in
the safety
system.
In the actuator housing a gear rack, fastened to the piston rod, and a
pinion transmit
the stroke of the actuator piston to the valve disk shaft and convert it in
a rotational
movement.
5.1.2 Pilot control system

The pilot control system with discharge amplifier for activating the
actuator and a so-
lenoid valve for the stroke test are flanged to the actuator. With adequate
pressure in
the safety system the stop valve is opened by the actuator.
If the pressure in the safety system is discharged, the pressure before the
discharge
amplifier drops and the backpressure, generated by the Belleville spring
assembly of
the actuator opens the valve plate of the discharge amplifier. The stroke
volume of
the actuator piston is discharged into the drain and the stop valve closes.
5.1.3 Stroke test

The stop valve must be subjected periodically to a stroke test in normal
operation.
must
5.2 Secondary steam control valve
The control valve is a butterfly valve that controls the steam flow to the
turbine in ac-
cordance with the flow rate required by the turbine controller. The control
valve as-
sumes a position corresponding to the relevant actuating signal.
In the case of inadmissible operating conditions or a shutdown the valve
shuts off the
steam supply to the LP turbine, together with the stop valve.
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MA -
HTGD693027V9005 -
Technical
Description
of the
Steam Turbine
The main parts of the valve are the housing with integral valve seat, the
eccentrically
supported valve disk, the actuator with pilot control and the angular
position trans-
ducer for position indication and adjustment.
5.2.1 Control valve actuator

The control valve actuator is a hydraulic actuator with end position
dampening for di-
rectly actuating the control valve. It can assume any position as
stationary position
over the entire stroke range. The actuator operates according to the "fail-
safe" prin-
ciple, i.e. the actuator closes the stop valve with spring force in the
case of a pres-
sure drop in the safety system.
In the case of inadmissible operating conditions or a shutdown the actuator
and the
coupled valve shuts off the steam supply to the turbine.
In the actuator housing a gear rack, fastened to the piston rod, and a
pinion transmit
the stroke of the actuator piston to the valve disk shaft and convert it in
a rotational
movement.
5.2.2 Pilot control system

The pilot control system, comprising discharge amplifier, proportional
valve with
power amplifier and integral stroke transmitter, is flanged directly to the
actuator. Via
the pressure below the actuator piston the proportional valve with power
amplifier
controls the position of the actuator in accordance with the electrical
input signal that
corresponds to the control valve position, required by the turbine
controller. This con-
trol can be configured at the power amplifier.
If the pressure in the safety system is discharged, the pressure before the
discharge
amplifier decreases and the backpressure, generated by the Belleville
spring as-
sembly of the actuator opens the valve plate of the discharge amplifier.
The stroke
volume of the actuator piston is discharged to the drain and the control
valve closes.
A feed and a discharge orifice are installed in the pilot control system.
The feed ori-
fice prevents emptying of the pilot control system and the control valve
actuator
when the control valve is closed. The discharge orifice causes slow closing
of the
control valve in the case of a failure of the proportional valve.
5.2.3 Stroke test

The control valve must be subjected periodically to a stroke test in normal
operation.
must
5.3 Steam strainer

The steam strainer is a strainer basket, arranged eccentrically in a
housing and de-
signed as a cylindrical perforated plate with welded-on fine screen. The
strainer bas-
ket acts as a flow equaliser, ensuring a uniform, twist-free steam supply
to the tur-
bine. The fine screen protects the turbine against solid particles.
en HTGD 693 000 V0140 A

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As the steam flows from the inside to the outside, the solid particles are
collected in
the strainer and can be easily removed.
6 BEARING PEDESTALS
6.1 Front bearing pedestal

The front bearing pedestal with a combined tilting pad thrust and journal
bearing is
mounted on a base plate, permitting displacement in axial direction.
The rotor turning gear is mounted on top of the bearing pedestal.
The base plate is secured on the foundation by foundation bolts via
adjustable sup-
ports and is fixed laterally and axially by retaining blocks cast into the
foundation.
Maintenance free sliding elements with low friction coefficients are inserted
between
the bearing pedestal support surface and the base plate. The sliding elements
can
be exchanged without requiring disassembly of the bearing pedestal.
Permanently
lubricated, adjustable keys guide the bearing pedestal axially on the base
plate.
The turbine casing is supported in the parting plane via claws on permanently
lubri-
cated, adjustable spherical seats and support keys with integral hold-down
bars that
prevent the turbine casing from lifting off due to reaction forces.
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MA -
HTGD693027V9005 -
Technical
Description
of the Steam
Turbine
5 4 1 2
3
CLKA0104_
A2455_

1 Bearing casing 4 Rotor turning gear
2 Thrust and journal bearing 5 Oil shield
3 Base plate
Fig. 6-1 Front bearing pedestal
The force of the turbine casing, acting vertically upwards, is transmitted to

the bear-
ing pedestal and taken up by retaining claws that are also secured by the
foundation
bolts of the base plate. The retaining and friction surfaces of the retaining
claws are
provided with maintenance-free sliding elements.
Bolted joints, which can be adjusted axially with spacer sleeves, connect the
turbine
casing and the bearing pedestal and permit free thermal expansion of the
turbine
and bearing pedestal. An adjustable guide is mounted at the faceside to the
turbine
for lateral guidance.
The lube oil supply and drain are of the tube-in-tube design. Oil shields are
fitted ra-
dially at the rotor penetrations.
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6.1.1 Combined thrust and journal bearing

The design of combined thrust and journal bearings according to the
hydrodynamic
principle ensures that the sliding machine parts do not come into contact
and offers
low friction losses at low space requirement. The bearings transmit axial
thrust forces
from both sides and part of the shaft weight to the bearing casing.
The bearing is centred with cylindrical pins and slightly clamped in the
bearing ped-
estal by fitted plates. Shims under the fitted plates permit adjustment of
the bearing.
A cylindrical pin is inserted in the upper part of the fitted plate to
protect the bearing
against turning.
The thrust bearing consist of a two-part bearing housing, held together by
hexagon
head bolts and thrust pads backed for damping with spring rings.
The fully enclosed journal bearing consists of two bearing shells, lined
with white
metal, centred with cylindrical pins and held together by socket head
screws. The
bearing is slightly clamped in the thrust bearing housing. A cylindrical
pin is inserted
in the upper fitted plate to prevent the bearing from turning.
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HTGD693027V9005 -
Technical
Description
of the Steam
Turbine

1 Journal bearing body, lower part 5 Spring ring
2 Journal bearing body, upper part 6 Set of pads
3 Bearing housing, lower part 7 Sealing ring
4 Bearing housing, upper part 8 Fitted plate
Fig. 6-2 Combined thrust and journal bearing
The lube oil for the bearing is supplied through a bore in the bearing housing
and the
lateral oil inlet at the bearing from where the oil passes to the inlet pocket
of the
bearing shells.
The oil leaves the bearing at both facesides along the entire shaft
circumference.
Discharge orifices and sealing rings keep the internal chamber of each thrust
bearing
side permanently filled with lubricating oil. This assure lubricating and
cooling of all
thrust bearing parts.
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The higher-loaded journal bearings have a jacking oil system that prevents
metallic
contact of bearing metal and bearing journal during turning gear operation,
startup
and rundown when a hydrodynamic film is not yet available. The friction
coefficient in
the bearings and the torque to be produced by the turning gear are thus
reduced
significantly.
6.2 Low pressure bearing casing

The gas-tight enclosed bearing casing with integral journal bearing is
installed in the
LP exhaust area. It is supported on the foundation by casing tubes, welded on
at an
angle of 80�. There is, however, no positive connection with the LP turbine
support.
Oil shields protect the LP shaft seal, inserted in a cone ring of the bearing
casing
cowling.
The lube oil and gland steam pipes and the electrical lines are laid in
tubes, welded
in horizontally in the outer casing, and routed to the bearing casing
cowling. The lube
oil supply and drain are of the tube-in-tube design. The bearing oil feed
orifice is in-
stalled in a flanged connection in the bearing oil supply pipe external to
the LP cas-
ing.
A pump, mounted externally on the lube oil supply unit, delivers the jacking
oil to the
journal bearing through a flow control valve, check valve and internal
jacking oil
pipes. The flow control valve maintains constant the adjusted volume flow in
order to
ensure rotor elevation during turning gear operation, startup and rundown.
The main oil pump is located in the LP bearing casing and is driven by gears
from
the turbine shaft.
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MA - HTGD693027V9005
-
Technical
Description
of the Steam
Turbine
5 6 2 1
4 CLCA0103A
1 Casing cowling 5 Shaft seal
2 Pocket-type journal bearing 6 Oil shield
3 Casing tube 7 Main oil pump
4 Bearing casing support
Fig. 6-3 LP bearing casing
The gland steam and leak-off systems and the vacuum in the lube oil tank via
the
lube oil return pipe ensure the required air circulation in the bearing
chamber.
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6.2.1 Pocket-type journal bearing

The design of the journal bearing according to the hydrodynamic principle
ensures
that the sliding machine parts do not come into contact and offers low
friction losses
at low space requirement. The bearing transmits part of the shaft weight to
the bear-
ing casing.
The fully enclosed bearing consists of two bearing shells, lined with white
metal, cen-
tred with cylindrical pins and held together by socket head screws. The
bearing is
slightly clamped in the bearing casing by fitted plates. Shims under the
fitted plates
permit adjustment of the bearing. A cylindrical pin is inserted in the
upper fitted plate
to prevent the bearing from turning.
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MA -
HTGD693027V9005 -
Technical
Description
of the Steam
Turbine

1 Protection against turning 4 Upper bearing shell
2 Fitted plate 5 Lower bearing shell
3 Shim
Fig. 6-4 Pocket-type journal bearing
The lube oil for the bearing is supplied through a bore in the bearing casing
and the
lateral oil inlet at the bearing from where the oil passes to the inlet pocket
of the
bearing shells. The oil leaves the bearing at both facesides along the entire
shaft cir-
cumference.
The higher-loaded journal bearings have a jacking oil system that prevents
metallic
contact of bearing metal and bearing journal during turning gear operation,
startup
and rundown when a hydrodynamic film is not yet available. The friction
coefficient in
the bearings and the torque to be produced by the turning gear are thus
reduced
significantly.
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7 ROTOR TURNING GEAR
7.1 General
The rotor turning gear WDE6016 is designed to operate with the electronic
turbine
control system.
4 5 6 7
1
2
CJAD0102_
A2471_

1 Drive pinion 5 Frequency converter
2 AC motor 6 Maintenance switch
3 Solenoid valve 7 Push button manual
operation
4 Handle
Fig. 7-1 Rotor turning gear
Local operation is possible in emergency cases only. This is in the event of

a failure
of the power supply, or if only sporadic turning is necessary during
maintenance
work. The turning gear, and all functional elements are mounted on or
fastened to
the thrust bearing pedestal.
7.2 Tasks
The turning gear has mainly the following tasks:
� Turning gear operation after rundown of the steam turbine
� Turning gear operation before re-starting the turbine
� Turning gear operation during maintenance work
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HTGD693027V9005 -
Technical
Description
of the
Steam Turbine
The ventilation of the blading, caused by turning the rotor line after
rundown or dur-
ing preheating before commissioning, results in a temperature equalisation
while
maintaining the shaft axis in the casings. This prevents temperature layers
and de-
formation of the casings and turbine rotors, ensuring safe startup without
rubbing.
The turning gear is stopped automatically after starting the steam turbine
and in the
event of a failure or shutdown of the lube oil supply. Incorrect operation is
excluded.
7.3 Design
The WDE6016 is an electrical rotor turning gear and consists of
� Frequency converter mounted on top of the gear motor.
� Pinion with right or left hand thread which moves on along a threaded
shaft.
� Solenoid valve to supply lube oil (1.5 bar) into an annular chamber in
order to en-
gage the pinion with the rotor gear.
� Spring to disengage the pinion from the rotor gear.
� Maintenance switch to shut off the power supply to the motor
� Illuminated push-button for manual operation
� Proximity switches for manual operation, to monitoring if the hand lever is
mounted and also if the pinion is engaged with the rotort gear.
� Terminal boxes for signals and solenoid valve / motor. The terminal boxes
are the
interfaces to the field cabling.
� Hand lever for manual operation in the case of electrical malfunctioning
8 TURBINE INSULATION
The turbine insulation restricts the heat flow that results from temperature
differences
due to convection and radiation of the heat-conducting media and materials.
It also
prevents heat loss of all plant components that carry steam or hot condensate
and
serves simultaneously as a protection against radiation and contact.
It also prevents inadmissible thermal stresses during cooling down of the
casings
and resultant asymmetric deformations by reducing the wall temperature
gradients of
the insulated parts.
To achieve a good contact of insulation and casings and prevent sagging of
the insu-
lating material, the insulation is secured on the casings. Reinforcements are
pro-
vided additionally at exposed points. To avoid air circulation, the
insulation must con-
tact the hot casings all over.
A hard-shell is applied to protect the surface against oil or impurities.
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9 TURBINE INSTRUMENTS
Various instruments are required for protecting the turbine, transmitting
selected pa-
rameters to the measured value processing system under different operating
condi-
tions and for monitoring and switching certain devices during operation.
The values measured by the instruments are transmitted to the control room
and
serve as a basis for the automatic operation of the plant. Selected
variables are
processed in the display units and recorders for long-term monitoring.
The incoming values are evaluated in the different processing systems and
com-
pared with the values determined during commissioning and specified for
operation.
For example, limit values for alarms, shutdowns, admissible or inadmissible
operat-
ing conditions, and also measured value that indicate certain conditions or
whether
commissioning can be started.
Continually measured and correctly interpreted measured values are the
basis for a
long service life of the turbine. Damage can be prevented.
9.1 Temperature sensors at turbines

9.1.1 Startup probes
Transient operation, such as startup, rundown and load changes, causes
thermal
stresses in addition to the existing stationary stresses due to pressure,
temperature
and centrifugal force. These additional thermal stresses must be limited in
order not
to reduce the useful life of the machine.
This is achieved by adhering to the permitted temperature gradients. The
resultant
admissible load gradients for the machine are determined as a function of
the steam
conditions and geometry.
To meet these requirements, special temperature sensors are installed in
the inlet
parts of the HP and LP turbines.
9.1.2 Thermocouples
Temperature sensors or thermocouples for measuring the temperature are
installed
in the bladings of all turbines. Temperature measurement is of particular
importance
in low-load operation in order to counteract the risks of ventilation and
resultant in-
admissible temperature increase in the blading.
9.2 Bearing temperature measurement

The bearing metal temperature and the oil drain temperature of the turbine
bearings
are measured at all bearing pedestals. The bearing metal temperature
measurement
is the most suitable criterion for monitoring the proper functioning of a
bearing.
The bearing metal temperature is measured with double-thermocouples in the
lower
bearing shells of journal bearings or load-bearing pads and at the top,
bottom and
both sides of the thrust bearing in the thrust pads.
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HTGD693027V9005 -
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Description
of the
Steam Turbine
The oil drain temperature measurement is the suitable means for monitoring
the lube
oil supply to the turbine bearings. Excessive temperatures indicate
inadmissible con-
ditions in the bearings or excessive oil supply temperatures.
Defined excessive temperatures trigger an alarm or a turbine trip.
9.3 Speed sensor

The electrical speed sensors are installed in the thrust bearing pedestal
and pulsed
via the gear ring of the rotor turning gear. The speed of the rotor line is
measured by
these sensors which protect against overspeed. When reaching inadmissible
speeds, the turbine is automatically shut down. The proper functioning of
the safety
system can be tested during operation with the help of these speed sensors
and cer-
tain safety elements.
9.4 Vibration pick-up

Smooth running of the machine depends largely on vibration-free operation
of the ro-
tor line. For measuring the relative vibration of rotors and bearing
casings, two induc-
tive vibration pick-ups are installed in each bearing casing. Equipped with
an addi-
tional device, these pick-ups permit also rebalancing of the turbine
rotors.
Defined excessive vibration values trigger an alarm or a turbine trip.
A transmitter for measuring the phase angle is installed additionally in
the thrust
bearing pedestal.
9.5 Expansion transmitter

9.5.1 Differential expansion transmitter
The differential expansion of bearings and turbine casings is measured and
com-
pared with these transmitters. The differential expansion is caused by the
difference
in mass and surface of the relevant components and does usually not yield
abnormal
values because it was taken into account in the design. The differential
values must,
however, be observed during quick loading or unloading of the machine.
9.5.2 Absolute expansion transmitter

The absolute expansion of every turbine casing, referred to the absolute
fixed point
of the turbine, is measured with these transmitters, fastened to the
bearing pedes-
tals. These values indicate the free thermal expansion and, in contrast to
the differ-
ential expansions, show the co-action of load and temperature gradients.
9.5.3 Shaft position monitor

The positive or negative displacement of the turbine rotor, referred to the
relative
fixed point of the turbine, is measured with the shaft position monitor,
fitted at the
thrust bearing pedestal. The measured values must be observed particularly
thor-
oughly during load surges and indicate the pressure behaviour in the
turbine.
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9.6 Pressure transmitter

Pressure transmitters are mounted on the LP outer casing for monitoring the
con-
denser pressure.
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MA - HTGD693027V9005 -
Technical
Description
of the Steam
Turbine
10 EXPLANATORY DESIGNATIONS
10.1 Turbine subassemblies

MAA10 HP turbine
MAA10CT005 Startup probe, HP turbine
MAA10CT010 Ventilation monitoring, HP turbine
MAA10HB100 HP/LP rotor
MAA10HA410 Stationary blading, HP turbine
MAA10HB410 Rotating blading, HP turbine
MAA12AA001 Live steam stop valve
MAA12AA011 Live steam control valve
MAA12BQ001 Swing arm support
MAC10 LP turbine
MAC10AA021 Vacuum breaking valve
MAC10BP010 Rupture diaphragm
MAC10HA420 Stationary blading, LP turbine
MAC10HB420 Rotating blading, LP turbine
MAC31AA001 Secondary steam stop valve
MAC31AA011 Secondary steam control valve
MAC80AA001 Water injection valve
MAD20 Thrust bearing pedestal
MAD21 Thrust/journal bearing
MAD50 LP bearing casing
MAD51 Pocket-type journal bearing
MAK21 Expansion sleeve coupling
MAK80 Rotor turning gear
10.2 Designation of the external connections

MAA10/20 Gland steam system, HP turbine
MAA10/25 Leak-off system, HP turbine
MAA12/01 Live steam supply, HP turbine
MAC10/20 Gland steam system, LP turbine
MAC10/25 Leak-off system, LP turbine
MAC31/01 Secondary steam supply, LP turbine
MAD20/50 Lube oil supply, thrust bearing pedestal
MAD50/50 Lube oil supply, LP bearing casing
10.3 Designation of code letters

A Endoscope opening
B Balancing opening
C Balance piston feedback
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Fig. 10-1 Turbine views
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WP4140
Blank Page
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HTGD693027V9005
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MA - HTGD690038V0001E -
Outage Preservation
of Steam Turbines
MA - HTGD690038V0001E -
Outage Preservation
of Steam Turbines
en HTGD 693 000 V0140 A 75

Revision History
Revision Content of Change
Document Pages
total :
E 97-04-22, Additional preservation measures, notes on generator omit-
-
ted
- -
(12)
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MA - HTGD690038V0001E -
Outage Preservation
of Steam Turbines
Contents
1 GENERAL
DESCRIPTION .......................................................................
...........................................79
1.1
Purpose............................................................................
........................................ 79
1.2 Definition of
terms .............................................................................
....................... 79
1.2.1 Short-term
shutdown ..........................................................................
......... 79
1.2.2 Long-term
shutdown...........................................................................
......... 79
2 REASONS AND EFFECTS OF
CORROSION .........................................................................
...........80
2.1
Reasons............................................................................
....................................... 80
2.2
Effects ...........................................................................
........................................... 81
3 PRESERVATION
MEASURES...........................................................................
.................................82
3.1 Preliminary
remark.............................................................................
...................... 82
3.2 Preservation with heated
air ...............................................................................
..... 82
3.3 Dry air method according to the adsorption
principle............................................... 82
4 DIMENSIONING THE DRY AIR
UNIT ..............................................................................
...................84
5 SUPERVISION DURING
SHUTDOWN ..........................................................................
.....................84
6 MEASURES BEFORE RESTARTING THE
TURBINE........................................................................85
7
SUMMARY ...........................................................................
................................................................85
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WP4110 & WP4140
Figures
Fig. 2-1 Vernon

curve .............................................................................
..................................... 81
Fig. 3-1 Basic diagram of regenerative adsorption
drying ........................................................... 83
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MA -
HTGD690038V0001E -
Outage
Preservation
of Steam
Turbines
1 GENERAL DESCRIPTION
1.1 Purpose
The objective of these guidelines is to prevent damage of steam turbosets
by corro-
sion which may take place when the plant is shut down.
A shutdown may be scheduled or not, the duration of the shutdown extending
from a
few days to several years.
1.2 Definition of terms

1.2.1 Short-term shutdown
A short-term shutdown is one during which the machines are out of service
owing to
a break-down or the need to carry out maintenance. In such cases no
preservation is
necessary as a rule.
1.2.2 Long-term shutdown

A long-term shutdown means that the plant is out of service for a longer
period. In
this case a distinction is made between plants kept on standby but which
are re-
quired to start up at short notice and plants, the duration of whose
shutdown can be
definitely planned in advance.
A long-term shutdown where the turboset is able to start up at short notice
occurs in
the following cases:
� Standby plants of various availability categories, which are normally not
running.
� Heating turbines which are only operated when need arises.
In this case only the main and auxiliary turbines are provided with
corrosion protec-
tion because the turboset must be ready for operation at short notice and
the preser-
vation equipment be dismantled quickly.
Lube oil and hydraulic systems are not preserved.
A long-term shutdown with planned duration occurs for example in:
� Turbines of sugar factories (seasonal operation)
� Plants whose commissioning is delayed or prohibited by official action
(approval
procedure) or other causes (modification of the boiler etc.).
In this case the lube oil system is also preserved with dry air.
Since the risk of irreparable corrosion damage is very great in the event
of a long-
term shutdown, preventive measures must be taken in good time. These
measures
must be simple, effective and inexpensive.
en HTGD 693 000 V0140 A
79
Measures for outage preservation may not seriously delay the

recommis-
sioning of a plant.
2 REASONS AND EFFECTS OF CORROSION

2.1 Reasons
Corrosion is an electro-chemical process, controlled by diffusion, which can
take
place on metal surfaces due to the simultaneous action of water and oxygen,
the
oxygen being dissolved in the water.
During shutdown corrosion can therefore take place on all turbine parts where
the
ambient air, which always contains a certain amount of water vapour, comes
into
contact with metal surfaces. The ability of the air to absorb water vapour
depends on
the temperature and pressure of the air.
If the temperature drops below a definite level - known as the dew-point - or
if an ob-
ject whose temperature is below the dew-point comes into contact with air,
water
drops form on its surface, and finally a film of moisture.
But corrosion is not necessarily associated with the presence of condensable
mois-
ture. Metal surfaces can, in principle, also corrode when they are only
exposed to an
atmosphere with a high humidity.
Of the various metals and alloys used in the construction of turbines, not
only carbon
steels but also alloy steels exhibit an inclination to corrode under certain
conditions.
The relationship between corrosion rate and the moisture content of the air
is not lin-
ear. From the curves plotted by W.H.J. Vernon (Fig. 2-1) it is evident that,
with pure
carbon steel for instance, the corrosion rate increases abruptly at a
relative humidity
(rel. hum.) of 60 %, while below about 35 % it tends towards zero.
This knowledge is based on years of experience and on measurements. For the
preservation of steel parts, the following statements can therefore be made:
� Below 70 % rel. hum. no mould is to be expected.
� Below 50 % rel. hum. hardly any corrosion occurs on cast, forged and rough-
machined parts.
� Below 35 % rel. hum. no corrosion takes place on highly polished carbon
steel
surfaces.
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MA -
HTGD690038V0001E -
Outage
Preservation
of Steam
Turbines
Weight increase (mg/dm2)
Relative
humidity
Fig. 2-1 Vernon curve
These figures apply to slightly polluted industrial atmospheres containing

not more
than 0.01 % sulphur dioxide. If the atmosphere contains a greater amount of
sulphur
dioxide SO2 (as in oil or coal fired power plants) or other pollutants such
as sodium
chloride, the curve shifts to the left into the region of low relative
humidity and be-
comes steeper.
To prevent corrosion in such cases, the humidity of the preserving air in
turbines and
directly connected heat exchanger equipment must be kept below 40 %.
This value applies taking into account the materials used.
2.2 Effects
Corrosion on the turbine leads to the following indications, which can
initiate dam-
age:
� The fatigue strength of the blading can be appreciably reduced by corrosion
which is one of the main causes of damage to LP blading.
en HTGD 693 000 V0140 A

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� The strength of the turbine rotors is considerably reduced by the notch

effect of
corrosion pits.
� Owing to the inhomogeneous corrosion layer, the heat transfer may be
affected,
resulting for example in temporary distortion of the rotor at temperature
changes
and vibration excitation.
� Corroded casing guides and supports may prevent individual components from
expanding.
� The corrosion layer impairs dismantling. Its removal incurs additional
work.
� For a turbine which has been in operation, there is also a further
corrosion hazard
resulting from deposits of chemical compounds, soluble in water, on rotors,
blade
carriers and blading. These deposits (sodium chloride, sodium hydroxide,
sul-
phates etc.), entrained in the steam circuit due to the penetration of
cooling water
or faulty operation of a condensate polishing plant, can also attack steel
with a
relative high resistance to corrosion during plant shutdowns.
3 PRESERVATION MEASURES
3.1 Preliminary remark
Two of the preservation methods that can be used are considered which are
both
based on reducing the amount of moisture at the endangered surfaces.
These are:
� Preservation with heated air
� Preservation with dry, dehumidified air using the adsorption method.
3.2 Preservation with heated air

In the case of the heated air method the ambient air is heated by a heater.
The rela-
tive humidity is reduced in this way, but the absolute humidity and thus the
dew-point
remain the same.
The heated air absorbs moisture, accompanied by a drop in temperature.
However, as soon as the air cools down to the dew-point due to the transfer
of heat
to the surroundings, condensation takes place once more on the colder parts
of the
plant. Since only some of the moisture is transferred to parts with a lower
tempera-
ture, the method is only suitable for preserving small components.
3.3 Dry air method according to the adsorption principle

The air to be dried has moisture removed by means of a sorption unit so that
after
dehumidification it has again a high capacity to absorb moisture. The
sorption unit is
continuously regenerated (dehumidified) with warm air.
82 HTGD 693 000 V0140 A
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MA -
HTGD690038V0001E -
Outage
Preservation
of Steam
Turbines
This method does not include the risk of repeated condensation because the
pre-
serving dry air generally has a relative humidity of only 10 - 20 %.
Fig. 3-1 shows the principle of a regenerative adsorption drier.
Fig. 3-1 Basic diagram of regenerative adsorption drying
This method of preservation has proved very successful in many large

installations
and is recommended by ALSTOM.
According to the experience gained to date, the following hints may be given
regard-
ing the practical application of the dry air method of preservation:
� Before salted turbines are shut down for a long time they should be washed
with
wet steam or condensate.
� Plants should have the moisture removed as quickly as possible following
their
being taken out of service. In most cases the residual heat accumulated by
the
rotor and casing is sufficient. The drying process can be accelerated by
evacuat-
ing the steam spaces.
� Preservation of the LP turbine(s) should start not later than 48 hours after
turbine
shutdown. This is particularly important for turbines with salt deposits.
The HP
and IP turbines are to be connected with the air drier as soon as their
metal tem-
perature is below 100 �C (212 �F).
� The part preserved with dry air may have to be sealed off from wet-preserved
parts, so as to prevent the dry air from receiving moisture by leakage.
� If it is necessary to separate the space of the LP turbine from that of the
con-
denser (periodic circulation of condensate during shutdown), a plastic foil
is laid
over the tubing of the condenser, thus separating the two spaces.
en HTGD 693 000 V0140 A

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� Parts of the system through which there is no flow are dried by diffusion.
Drying of the turbine internals can be accelerated by operating the

turning
gear.
� Suitable points for the intake of dry air may be simple stubs on casings and
cross-
over pipes. As outlets the balancing openings in the turbine, manholes in
the
condenser, drain pipes and shaft seals are used.
� If the dry air shall also flow through the steam pipes, connected to the
turbine
casing, reheat pipe, bleed pipe, the corresponding valves must be left open.
Con-
trol and stop valves must be blocked in the open position and the plates of
the
check valves dismantled or held open.
� The gland steam and leak-off systems are preserved adequately by the dry air
emerging through the shaft seals of the turbine.
� The lubricating oil system is preserved with dry air fed through the vent
pipe of
the oil tank. The dry air flows through the oil return pipe into the bearing
housing,
thereby protecting the bare parts of the turbine rotors which are sensitive
to cor-
rosion.
� The control fluid tank has to be preserved with dry air only if not filled
with fluid.
� If the lube oil and control fluid tanks are preserved with dry air, the pipe
stubs on
the suction fans must be closed provisionally.
� Shaft components outside the bearing housings or turbine casings must be
pro-
tected by "Tectyl 506" (or an equivalent medium).
4 DIMENSIONING THE DRY AIR UNIT

Since preservation of the installation during shutdown is usually restricted
to certain
periods, the air drier and its accessories (spiral hoses, stop valves,
distributor) ought
to be mobile, so that they may be used for various installations.
The primary factor governing the dimensioning of the drying unit is the size
of the
metal surface in the systems to be preserved. Since in many cases this is
difficult to
determine it is common practice to base calculations on the volume of air in
the plant
to be preserved, allowing for 1 - 2 changes of air per hour.
5 SUPERVISION DURING SHUTDOWN

� The relative humidity of the dry air leaving the plant being preserved
should be
regularly measured and must never exceed 40 %.
� If lubricating oil and hydraulic fluid is left in the tanks, samples should
be taken
every 6 months and examined for moisture content.
� Twice a month the lubricating oil pumps, jacking oil pumps and control oil
pumps
should be started for a few hours, provided the tanks were not emptied.
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MA -
HTGD690038V0001E -
Outage
Preservation
of Steam
Turbines
� Every 3 months accessible parts of the turbine should be examined visually

and
with an endoscope for signs of corrosion.
6 MEASURES BEFORE RESTARTING THE TURBINE

� All preservation measures must be revoked.
� All auxiliary devices, including the safety and control equipment of the
turboset,
are checked to make sure they are functioning correctly.
� At least 48 hours prior to restarting the plant, the turning gear should be
started in
order to restraighten the turbine and generator rotors.
This is not required if the turning gear has been in operation twice
a month
for several hours.
� If the shutdown lasts more than one year, additional specific measures must
be
taken which have to be specified in each case separately together with
ALSTOM.
7 SUMMARY
Tests and practical experience prove that corrosion on turbosets can be
reliably
avoided, if the air humidity in the ambient air can be maintained at less than
40 %
relative humidity.
This condition is easy to fulfil, if pre-dehumidified air is used for the
preservation. The
application of warm air is not sufficient in most cases.
The necessary adsorption apparatus is very reliable, easy to operate and
requires
almost no maintenance.
The necessary material for the preservation equipment is negligible. An
optimal use
is possible if the requirements are defined already in the planning phase.
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HTGD690038V0001E
86 HTGD 693 000 V0140 A en

MA - HTMD690133V0001B -
Removing Salt and Silica from Steam Turbines
MA - HTMD690133V0001B -
Removing Salt and Silica from
Steam Turbines
en HTGD 693 000 V0140 A 87

Revision History
Revision Content of Change Document
Pages
total :
B 97-04-22, New cleaning method, restructuring of the text -
- - (16)
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MA - HTMD690133V0001B -
Removing Salt and Silica from Steam Turbines
Contents
1
GENERAL ...........................................................................
.................................................................91
2 REMOVING WATER-SOLUBLE
DEPOSITS ..........................................................................
............91
2.1 Flushing with saturated

steam .............................................................................
.... 91
2.2 Flushing with live
steam..............................................................................
............. 93
2.3 Washing with preheated feed
water......................................................................... 94
3 REMOVING DEPOSITS, INSOLUBLE IN
WATER .............................................................................
95
3.1 Blasting with aluminium

powder.............................................................................
.. 95
3.2 Glass
flushing ..........................................................................
................................ 96
3.3 Wet blasting with
slurry ............................................................................
................ 96
3.4 Dry blasting with fine
sand ..............................................................................
......... 97
3.5 Blasting with fine
grain .............................................................................
................ 97
3.6 Dry blasting with fly ash or nut
shells....................................................................... 97
4
PROCEDURE .........................................................................
.............................................................99
4.1 Wet
cleaning ..........................................................................
.................................. 99
4.2 Dry
cleaning ..........................................................................
................................... 99
4.3
Tendency ..........................................................................
....................................... 99
4.4 Safety
advices............................................................................
.............................. 99
5
TESTS..............................................................................
..................................................................100
6
PRESERVATION ......................................................................
.........................................................100
7 ADDRESSES OF
SUBSUPPLIERS ......................................................................
............................101
7.1 Aluminium
powder ............................................................................
..................... 101
7.2 Glass
beads .............................................................................
.............................. 101
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WP4110 & WP4140
Figures
Fig. 1 Flushing with external flushing

steam..............................................................................
.. 92
Fig. 2 Flushing with live
steam .............................................................................
....................... 94
Fig. 3 Protective
tent...............................................................................
..................................... 95
Fig. 4 Arrangement of the mixing
nozzle ............................................................................
......... 98
Standstill preservation of steam turbines
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MA - HTMD690133V0001B
-
Removing Salt and Silica from Steam
Turbines
1 GENERAL
Depending on the live steam pressure and temperature, the boiler design and
the
feed water conditioning, salt and silicate deposits can accumulate on the
steam-
exposed parts of the turbine, particularly the blading.
This not only implies the danger of corrosion (corrosion pits or pitting
corrosion) but
also leads to a reduced swallowing capacity of the turbine, higher flow
losses and a
decrease in output due to a reduced blading efficiency. In extreme cases, the
proper
functioning of the stop and control valves can be endangered.
The change of the pressure upstream of the blading as a function of time and
steam
flow rate indicates the degree of fouling.
The deposits are either soluble or insoluble in water, depending on the
composition
of the salts:
� deposits containing phosphate are soluble
� deposits containing silicon are insoluble.
2 REMOVING WATER-SOLUBLE DEPOSITS

For removing water-soluble deposits in steam turbines, ALSTOM recommends
flush-
ing with saturated steam, live steam or washing with preheated feed water.
This
should include cleaning of the boiler. See the instructions of the boiler
supplier.
2.1 Flushing with saturated steam

Caution
Turbine speed: max. 600 1/min.
Higher speeds can damage the blading.
If saturated steam of satisfactory quality is available as flushing steam in
the plant, it
is introduced between the live steam shutoff gate valve and the stop valve
(see Fig.
1). For the flushing procedure, the stop and the control valves are fully
open. This
ensures a good steam admission to the blading, counteracting the danger of
over-
heating of the saturated steam due to throttling.
Turbine flushing may not be started until the temperature of the casing has
fallen to
less than 180 �C (356 �F) and the absolute expansion has decreased to 30 % of
its
maximum value.
By opening the hand valve in the saturated steam supply line, the steam
necessary
for flushing is throttled to such an extent that the turbine speed is between
500 and
600 1/min.
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Fig. 1 Flushing with external flushing steam
The saturated steam state of the flushing steam is controlled with the
operating in-
struments of the turbine before the stop valve. The washing process begins
when
the casing temperature reaches the corresponding saturated steam temperature.
During the flushing process, all drains of the turbine casing must be open.
In the case of condensing turbines it is advantageous to switch the condensate
after
the pump to discharge into the dirty-water duct. The condenser is only
partially
evacuated so that the maximum exhaust steam temperature of 80�C is not ex-
ceeded. The cooling water system shall be in operation.
Note
During the entire flushing process the temperature in the exhaust
steam
branch must be monitored.
In the case of back-pressure turbines, the back-pressure gate valve is closed,
and
the safety valve is fully open, thus allowing the exhaust steam to flow to the
outside.
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-
Turbines
Note
This guarantees that these salts do not burden the circuit any more.
In order to keep the flushing time as short as possible it is necessary to
continuously
examine the flushing steam flowing out from the drains and the exhaust
section by
means of conductivity measurements and chemical analyses. Flushing can be re-
garded as completed when the conductivity or the salt contents remain almost
con-
stant over a period of approximately 30 minutes.
Note
Experience has shown that this state is reached after 6 or 8 hours.
2.2 Flushing with live steam

Caution
Turbine speed: max. 600 1/min.
Higher speeds can damage the blading.
If no saturated steam is available, the live steam is throttled by means of
the shutoff
device in the live steam pipe, preferably using a bypass, and, after the
throttling
point, brought to saturated steam values by injecting condensate.
The aforementioned shutoff device is also used for controlling the speed. If
a water
separator is available, the water is injected directly into the water
separator (see Fig.
2).
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93
Fig. 2 Flushing with live steam
Otherwise proceed as described in section 2.1.
2.3 Washing with preheated feed water

Following a massive salt contamination, caused e.g. by an ingress of salt
water in
the condenser, rough cleaning of the turbine by repeatedly filling it with
preheated
feed water up to the shaft seals has a good cleaning effect.
After filling, the turbine rotor has to be turned continuously for
approximately 6 hours
by means of the turning gear. This procedure has to be repeated four times.
The
disadvantage of this procedure is that the stationary blading is cleaned only
inade-
quately.
A subsequent cleaning as described in section 2.1 is therefore recommended.
Note
It is recommended to plan and carry out this type of cleaning in
coopera-
tion with ALSTOM. The maximum metal temperature should not exceed
80�C when starting the cleaning.
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Turbines
3 REMOVING DEPOSITS, INSOLUBLE IN WATER

3.1 Blasting with aluminium powder
Note
This process can be applied as a wet or dry process.
The blast medium is silicate-free aluminium powder (AI203), grain size 80
0.15 to
0.25 mm, Mohs hardness 9. The blast intensity is optimised at the beginning
(e.g.
Almen test strip) and maintained constant during the entire cleaning process.
The
surfaces cleaned with aluminium powder have a perfect roughness.
There is a danger of damaging sensitive components by roughening the surface
if
the process is applied inadequately. A double-wall tent according to Fig. 3
shall be
put up to separate the operating field on the machine floor and to prevent
dust and
blast medium from entering the machines and buildings.
Fig. 3 Protective tent
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Note
Breathing equipment is absolutely necessary for the operating
personnel.
Minor cracks may be smeared over with aluminium powder which makes
difficult an early detection of cracks by the dye penetrant test.
3.2 Glass flushing

Note
Depending on the type and extent of fouling glass beads with a maximum grain
size
of 0.5 mm are used as blast medium.
Due to the ball shape and the low pressure, up to 10 bar at the most, no base
mate-
rial losses have been ascertained. Moreover, alterations of the original
surface
roughness were not measured.
Note
Glass flushing is a very mild, thorough and quick cleaning method.
3.3 Wet blasting with slurry

This procedure is very similar to blasting with aluminium powder. The blast
medium
is alum earth, highly diluted with water, which is supplied through a nozzle
at high
pressure (200 to 400 bar).
Caution
This process may only be applied by qualified personnel using
blasting
equipment with special mixing nozzles. An incorrect blast medium
mass
flow may cause permanent damage or destruction, especially of the
blad-
ing.
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Turbines
3.4 Dry blasting with fine sand

Note
This process should only be used in exceptional cases.
A fine, silikate-free sand granulate (Si02), Mohs hardness 7, grain size ASTM
grit
200, or finer lees or equal 0.1 mm, is used as blast medium, with a
compressed air
pressure of 5 to 6 bar.
Caution
This process may only be applied by qualified personnel, observing
the
official health regulations. An incorrect blast medium mass flow may
cause
permanent damage or destruction, especially of the blading.
3.5 Blasting with fine grain

Note
There is only an insignificant difference between this procedure and the fine
sand
blasting.
The blast medium is electrical corundum dust which is applied at a compressed
air
pressure of 6 to 7 bar.
Caution
This process may only be applied by qualified personnel, observing
the
official health regulations. An incorrect blast medium mass flow may
cause
permanent damage or destruction, especially of the blading.
3.6 Dry blasting with fly ash or nut shells

This procedure can be applied with a minimum of equipment and thus be used
even
in the most remote regions.
It is advisable to take outside the parts to be cleaned. The fine fly ash is
flinged
against the dirty parts by means of compressed air.
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Note
Care must be taken that only the deposits are removed from the
machine
parts.
See Fig. 4 for the design of the mixing nozzle.
The experience gained so far has shown that the described procedure is a
success.
It permits the removal of deposits without noticeable damage to the metallic
surface.
Fig. 4 Arrangement of the mixing nozzle
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Turbines
4 PROCEDURE
4.1 Wet cleaning
Advantages:
� quick cleaning effect
� no development of dust
Disadvantages:
� pretentious in applicationblast intensity --> qualified operating personnel
� subsequent washing for removing the residues
� danger of rust film
� sections which are not blasted have to be covered
4.2 Dry cleaning

Advantages:
� smooth cleaning method
� final cleaning with compressed air
Disadvantages:
� development of a considerable amount of dustprotective tent, protective
clothing,
breathing equipment and protective mask required.
4.3 Tendency
The customers tend to apply the dry procedures.
The necessary quantity of blast medium depends on the process selected, the
size
of the surface to be cleaned and the degree of fouling. The quantity is
determined by
the supplier of the blast medium.
4.4 Safety advices

As a rule, the "General safety instructions of ALSTOM POWER" apply to all
proce-
dures. In addition, the relevant rules of the country and the official health
regulations
have to be observed, and protective clothing, protective masks and breathing
equipment be worn.
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99
Note
Take note to the guidelines and instructions of the blast medium
manufac-
turer.
5 TESTS
After the blasting, the cleaned surfaces must be inspected visually. ALSTOM
re-
commends to carry out a dye penetrant test in order to detect in time
possible cracks
on the rotating blading.
6 PRESERVATION
Note
If the turbine is not put into operation immediately after cleaning,
corrosion
must be prevented by using effective preservation agents.
ALSTOM recommends the use of a regenerative absorption dryer in accordance
with
the instructions "Standstill preservation of steam turbines".
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Turbines
7 ADDRESSES OF SUBSUPPLIERS
7.1 Aluminium powder
MI - Metal Improvement Company, Inc.
Otto-Hahn-Strasse 3
Postfach 1708
D-59423 Unna
BAUMONTA AG BAUMONTA AG
Furrengasse 2 Kaiserstrasse 26
Postfach 546 D 66121 Saarbr�cken
CH-6002 Luzern
7.2 Glass beads

Haumann
Hochdruck-Reinigungstechnik
Ostkirchstrasse 95
D-44269 Dortmund
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HTMD690133V0001B
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MA - HTGD090550V0001F -
Evaluation of Vibrations in Steam Turbosets > 50 MW
MA - HTGD090550V0001F -
Evaluation of Vibrations in Steam
Turbosets > 50 MW
en HTGD 693 000 V0140 A 103

Revision History
Document Pages
total :
F 97-04-24, Integration of evaluation criteria, re-structuring of the
text -
- -
(12)
104 HTGD 693 000 V0140 A

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MA - HTGD090550V0001F -
Evaluation of
Vibrations in Steam Turbosets > 50 MW
Contents
1
SUBJECT ...........................................................................
................................................................107
1.1 Scope of
application........................................................................
....................... 107
1.2 Monitoring the turboset
operation .........................................................................
. 107
1.3 Monitoring
equipment .........................................................................
................... 107
1.4 Balancing the turbine
rotors ............................................................................
....... 107
2
DESIGN.............................................................................
.................................................................108
2.1 Measuring
equipment .........................................................................
................... 108
2.2 Measured value
processing ........................................................................
........... 108
2.3
Options............................................................................
....................................... 109
3 EVALUATING THE VIBRATION
VALUES ............................................................................
............109
3.1 Description of the measured value

zones.............................................................. 109
3.2 Shaft
vibrations ........................................................................
.............................. 110
3.3 Bearing casing
vibrations.........................................................................
.............. 111
3.4 Conversion
factors ...........................................................................
...................... 111
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WP4140
Figures
Fig. 1 Arrangement of the vibration

transmitters ......................................................................
. 108
Fig. 2 High natural frequency foundations, group
G.................................................................. 112
Fig. 3 Low natural frequency foundations, group
T ................................................................... 113
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HTGD090550V0001F -
Evaluation of Vibrations in Steam Turbosets >
50 MW
1 SUBJECT
The measurement of the steam turboset vibrations is required in order:
� to monitor the turboset operation
� to balance the rotor line.
1.1 Scope of application

� Power plant steam turbosets > 50 MW
� Steam turbines for driving feed pumps, fans etc.
1.2 Monitoring the turboset operation

Monitoring the turboset operation has the following aims:
� to indicate deviations from the normal vibrational behaviour
� to initiate an alarm when reaching defined, excessive vibration values
� to shut down the turbosets when reaching defined, inadmissible vibration
values
1.3 Monitoring equipment

The monitoring equipment comprises the following:
� Measuring instruments with vibration transmitters
� Evaluation unit
� Recorder and display in the control room
� Alarm initiation
� Turbine trip
1.4 Balancing the turbine rotors

The existing measuring equipment can be provided upon request with an
additional
device which permits balancing of the rotor line.
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2 DESIGN
2.1 Measuring equipment
As a rule, ALSTOM steam turbosets > 50 MW are equipped with 2 transmitters
per
bearing for monitoring the shaft vibrations.
The vibrations of the shaft relative to the bearing casing are measured by
contact-
less transmitters which are arranged as shown in Fig. 1.
Fig. 1 Arrangement of the vibration transmitters
A pick-up for measuring the phase angle is usually installed additionally at

the thrust
bearing casing.
2.2 Measured value processing

Display in the control room is always via the left, recording always via the
right
measuring level. In both cases, a maximum value selection is not made.
The principle of maximum value selection is applied when processing both
measured
values.
The greater of the two measured values is processed for initiating

an
alarm or a required turbine trip.
If necessary, the phase angle can be scanned, and upon customer request be
indi-
cated or recorded.
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MA -
HTGD090550V0001F -
Evaluation of Vibrations in Steam Turbosets >
50 MW
2.3 Options
Upon customer request, deviations from the standard or additional devices are
pos-
sible, such as for example:
� Measurement of the bearing casing vibrations
� Extension of the shaft vibration measurement
� Measurement of the absolute shaft vibration
� Additional device for balancing
� Extended measured value processing
3 EVALUATING THE VIBRATION VALUES

Vibrations are evaluated taking into account their frequency.
The evaluation is based on the measured shaft and bearing casing vibra-tions,
re-
ferred to the measured value zones.
3.1 Description of the measured value zones

Zone A
The measured values of newly commissioned machines should lie in zone A.
Zone B
Long-term operation of machines whose measured values lie in zone B is
permitted.
Zone C
Vibration values which lie in zone C are usually alarm values which require
remedial
action. As a rule, the machine can be operated with these values for a
limited period
of time. Remedial action can be taken at a suitable time.
The alarm values are generally set 25% higher than the value
measured in
normal operation.
The alarm values may not however be set higher than the lower limit value of
zone
C.
Zone D
A turbine trip is required if the vibration values lie in zone D, i.e. if
they exceed the
upper limit value of zone C.
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109
CAUTION
Measured values which lie in zone D are regarded as high enough
to
cause damage to the turboset.
The values for alarm and turbine trip have to be specified and set taking
into account
the above mentioned stipulations.
3.2 Shaft vibrations

A distinction is made between relative and absolute shaft
vibrations.
The recommended values listed in
Table 1 for relative vibrations and
Table 2 for absolute vibrations
are taken from ISO/DIN 7919 Part 2.
VDI recommendations for information:
� VDI 2059 Sheet 2, edition 1990, recommends to use these values also when
measuring the peak-to-peak vibrations in two directions.
Table 1
Recommended values for maximum relative shaft vibration amplitude in
micrometer
zero-to-peak amplitude (EA).
For limits Shaft speed (rpm)
of zones, 1'500 1'800 3'000 3'600
see 3.1 Maximum vibration amplitude
A/B 50 45 40 38
B/C 100 93 83 75
C/D 160 145 130 120
Table 2
Recommended values for maximum absolute shaft vibration amplitude s in
microme-
ter zero-to-peak amplitude (EA).
For limits Shaft speed (rpm)
of zones, 1'500 1'800 3'000 3'600
see 3.1 Maximum vibration amplitude
A/B 60 55 50 45
B/C 120 110 100 90
C/D 190 175 160 145
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MA -
HTGD090550V0001F -
Evaluation of Vibrations in Steam Turbosets
> 50 MW
3.3 Bearing casing vibrations

The bearing casing vibrations are evaluated in accordance with VDI2056,
edition
1985, and ISO 3945.
The evaluation criteria for high natural frequency foundations of group G are
shown
in Fig. 2.
The evaluation criteria for low natural frequency foundations of group T are
shown in
Fig. 3.
3.4 Conversion factors

� Conversion factor for micrometer zero-to-peak amplitude (EA) to mil DA =
12.7;
1 mil DA = 12. 7 EA.
� Conversion of vibration amplitude in vibration velocity Veff:
Veff = mm/s
f = frequency of shaft, e.g 50 s-1
s = mm EA
VDI classification scale for bearing casing vibrations of turbosets on heavy,

high
natural frequency foundations.As per VDI 2056 (1985) / ISO3945
en HTGD 693 000 V0140 A

111
Fig. 2 High natural frequency foundations, group G
VDI classification scale for bearing casing vibrations of turbosets on low

natural fre-
quency foundations (especially light foundations).As per VDI 2056 (1985) /
ISO 3945
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MA -
HTGD090550V0001F -
Evaluation of Vibrations in Steam Turbosets
> 50 MW

A very good B acceptable
C alarm initiation D inadmissable
Fig. 3 Low natural frequency foundations, group T
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Blank Page
HTGD090550V001F
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MA - HTGD090486V0001G -
Steam Purity Requirements
for Turbine Operation
MA - HTGD090486V0001G -
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Revision History
total :
G 07-10-05, Restructuring of the text -
- - (10)
116 HTGD 693 000 V0140 A en

MA - HTGD090486V0001G -
Contents
1
INTRODUCTION.......................................................................
.........................................................119
2 STEAM PURITY
REQUIREMENTS ......................................................................
............................119
2.1 Condensing turbines with superheated

steam....................................................... 119
2.2 Condensing turbines with nuclear-generated saturated
steam.............................. 120
2.2.1 Boiling water
reactors...........................................................................
..... 120
2.2.2 Pressurized water
reactors........................................................................
121
2.3 Backpressure
turbines ..........................................................................
................. 121
2.4 Special
cases..............................................................................
........................... 121
3 CAUSES AND ACTIONS IN THE CASE OF
DEVIATIONS ..............................................................122
3.1 First
commissioning .....................................................................
.......................... 122
3.2 Unforeseeable
situations ........................................................................
............... 122
3.2.1 Impurity deposits in the
turbine ................................................................. 122
3.2.2 Impurity deposits in the turbine
valves ...................................................... 122
3.2.3
Deposits ..........................................................................
.......................... 122
3.2.4 Acid
conditions ........................................................................
.................. 122
3.2.5 Degradation of the water / steam
separation ............................................ 123
4 SUPERVISION OF THE STEAM
PURITY.............................................................................
............123
5
REFERENCES.........................................................................
..........................................................123
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WP4110 & WP4140
Figures/Tables
Table 1. Steam purity for condensing turbines with superheated steam (N = normal
operation limit, S = turbine shutdown
limit) ...................................................................... 120
Table 2. Steam purity for boiling water reactors (N = normal operation limit, S =
turbine
shutdown
limit) ............................................................................
..................................... 120
Table 3. Steam purity for pressurized water reactors with saturated steam (N =
normal
operation limit, S = turbine shutdown
limit) ...................................................................... 121
Removing salt and silica from steam turbines
Outage preservation of steam turbines
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MA -
HTGD090486V0001G -
Steam Purity
Requirements
for Turbine
Operation
1 INTRODUCTION
Impurities contained in the steam may cause deposits and corrosion in steam
tur-
bines, adversely affecting their functioning. These problems can usually be
avoided
when observing the recommendations listed below.
The values stated in the tables are maximum values. The effective values
should be
kept lower whenever possible.
2 STEAM PURITY REQUIREMENTS

This specification is aimed at providing sufficient protection of steam-
exposed com-
ponents against deposits and corrosion in areas with superheated steam and
against
corrosion, corrosion fatigue, stress corrosion as well as flow-accelerated
corrosion in
wet steam areas.
The specification is based on the VGB "Guidelines for Feed Water, Boiler
Water, and
Steam Quality for Power Plants / Industrial Plants" R450Le, issued 2004, and
on the
experience gained by ALSTOM. It is adapted to the usual modes of operation of
the
steam generating systems and is applicable to fossil and nuclear-fuelled
plants.
The specification gives limits of good practice for normal operation (N), a
turbine
shutdown value (S) at which the turbine should be shut down, and limits for
plant
startup. Action levels are not given because they need consideration of the
chemistry
of the whole steam / water cycle and therefore have to be developed
specifically for
each plant or plant type.
If steam quality is outside normal operation levels, then the reason for the
worsening
steam quality must be determined and corrected as soon as practicable, at
least to
within the normal operation limits.
2.1 Condensing turbines with superheated steam

In addition to the requirements mentioned in Table 1, ALSTOM requires that
the tur-
bine should not be exposed to a liquid phase with an acidic pH value.
In the case of a warm start, the values for normal operation shall be
attained within 2
hours, and in the case of a cold start within 8 hours. During start-up the
values
should have a declining tendency.
en HTGD 693 000 V0140 A
119
The steam purity requirements are identical for base load, peak load and
industrial
condensing turbines.
Parameter Unit N
S Startup
Conductivity after cation exchanger @ 25�C * S/cm < 0.20
>1 <1
Sodium as Na a) boiler water PO4 0 -2 mg/kg ** g/kg <5
- < 10
b) boiler water PO4 > 2 mg/kg ** g/kg < 10
- < 20
Silica as SiO2 *** g/kg < 20
- < 100
Iron as Fe g/kg < 20
- < 100
Copper as Cu a) 150 bar g/kg <3
- < 10
b) > 150 bar g/kg <1
- < 10
Table 1. Steam purity for condensing turbines with superheated steam (N =

normal
operation limit, S = turbine shutdown limit)
* Additional tolerance of maximum 2 S/cm is given for carbon dioxide.
** In case of boiler water phosphate treatment > 2mg/kg PO4 a higher Na

content in steam
is tolerated as phosphates are considered as being non-corrosive to the
turbine. For all
other boiler water treatments, the lower limit is applicable.
*** Time permitted above 20 g/kg l: [hours] * [g/kg - 20] < 105. If this
time has expired, sil-
ica deposits may be expected. Checking turbine pressure and efficiency
as well as tur-
bine cleaning should be considered.
2.2 Condensing turbines with nuclear-generated saturated steam

2.2.1 Boiling water reactors
Parameter Unit N
S Startup
Conductivity @ 25�C S/cm < 0.10
- -
Mechanical Carryover * % < 0.5
- -
Table 2. Steam purity for boiling water reactors (N = normal operation

limit, S = tur-
bine shutdown limit)
* Percentage of reactor water carried along in the live steam.

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MA -
HTGD090486V0001G -
Steam Purity
Requirements
for
Turbine Operation
2.2.2 Pressurized water reactors

Parameter Unit N S
Startup
Conductivity after cation exchanger @ 25�C * S/cm < 0.20
- <1
Sodium as Na g/kg <10
- < 10
Mechanical Carryover ** % < 0.5
- -
Table 3. Steam purity for pressurized water reactors with saturated steam
(N = nor-
mal operation limit, S = turbine shutdown limit)
* Additional tolerance of maximum 2 S/cm is given for carbon dioxide.
** Percentage of steam generator water carried along in the live steam.
In addition to the requirements listed in Table 3, ALSTOM must be consulted

if dis-
solved solids or compounds of boron are used as conditioning agent at any
place in
the secondary circuit.
The content of sodium in the steam may be calculated from the composition
of the
steam generator water and the mechanical carry-over.
2.3 Backpressure turbines

The impurities dissolved in the steam deposit in the turbine during steam
expansion.
� Volatile acids are separated with the first condensate. There will
therefore be no
acid corrosion in backpressure turbines if the exhaust steam is
sufficiently super-
heated. Note: acids start condensing above the steam saturation line.
Sulfuric
acid may already condense at temperatures that are above 300�C
� Solid matters deposit if their solubility limits is exceeded. The
solubility decreases
during steam expansion.
In the case of backpressure turbines some of the values mentioned in Table
1 may
thus be exceeded under certain circumstances. However, this is only
permitted if the
composition of the steam is known and in accordance with the steam data at
the tur-
bine exhaust. These values must be defined plant-specifically.
2.4 Special cases

A higher degree of impurities can possibly be tolerated for turbines with
low main
steam pressure and / or temperature, lower stress, special materials or
steam com-
position. ALSTOM specifies the steam purity plant-specifically in such
cases.
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121
3 CAUSES AND ACTIONS IN THE CASE OF DEVIATIONS

3.1 First commissioning
During initial commissioning or after extensive boiler modifications it is
usually not
possible to respect the values given in this specification. These values
can be at-
tained and damage to the turbine be avoided by adequate cleaning of the
water /
steam circuit.
3.2 Unforeseeable situations

Unexpected events, such as cooling water leakage or attemperation injection
of con-
taminated feedwater, may cause an overrun of the limits and increase the
risk of de-
posits and corrosion in the turbines. The contamination and its cause must
therefore
be eliminated as soon as possible and the consequences be minimized by
taking
preventive measures.
3.2.1 Impurity deposits in the turbine

Impurity deposits in the turbine like metallic oxides, salts, silica, and
hardness resi-
dues etc. can cause poor operating behavior and decreased efficiency of the
turbine.
These deposits can usually be removed by specific measures.
3.2.2 Impurity deposits in the turbine valves

Impurity deposits in the turbine valves can cause blockage of the turbine
steam
strainers and sticking / seizure of the stop and control valves. This also
occurs when
voluminous oxidation or corrosion products deposit in the valve between
spindle and
bushings. If this cannot be excluded, the function of the valves must be
checked
daily.
3.2.3 Deposits
Deposits of water-soluble and hygroscopic materials may cause corrosion
during pe-
riods when the turbine is shutdown if humidity exists. Dry air preservation
is recom-
mended for long periods of shutdown. The cause of the deposits should be
elimi-
nated. Depending on the nature, severity and frequency of occurrence of the
depos-
its it may be recommended to wash the turbine.
3.2.4 Acid conditions

Acid conditions can cause severe corrosion and must be avoided. Acids can
enter
the circuit via the make-up water or the water polishing plants or be
formed in the
circuit by thermal decomposition of organic material. They can also be
formed by
cooling water ingress into the condensate polishers when the anion
exchanger has a
122 HTGD 693 000 V0140 A

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MA -
HTGD090486V0001G -
Steam Purity
Requirements
for Turbine
Operation
larger ionic leakage than the cation exchanger. Most anions of concern are
volatile in
steam generators with volatile conditioning and condense in the steam
turbine, creat-
ing a very corrosive environment.
3.2.5 Degradation of the water / steam separation

Degradation of the water / steam separation in drum boilers may cause
excessive
carry-over of boiler water droplets (i.e.dissolved solids) or even of
boiler water in the
case of a rapid pressure drop. Water / steam separation must first be
ensured by de-
sign measures and subsequently with periodic inspections / maintenance of
the
separators, water level instrumentation etc..
4 SUPERVISION OF THE STEAM PURITY

The steam purity requirements given in the Tables should be monitored.
A representative steam sample should be continuously withdrawn from live
steam
and condensed in a cooler.
Cation conductivity: Continuous measurement of conductivity, after the
sample has
passed through a strong acidic cation exchanger in the H+ form
All other parameters: periodic laboratory analyses of grab samples. The
frequency is
determined by the observed stability of the values; normally one analysis
per day is
sufficient.
If steam purity monitoring equipment is not available, then the Operator
must ensure
that alternative parameters are available. The operator must be able to
demonstrate
that such alternative parameters truly reflect steam purity.
Records of the steam purity shall be maintained for the life of the
turbine.
In addition to maintaining the steam purity within the specified values, it
is also nec-
essary to monitor and maintain the chemistry of the whole steam / water
cycle within
acknowledged guidelines and design criteria.
5 REFERENCES
International Electrotechnical Commission (IEC) Technical Specification TS
61370
"Steam turbines - steam purity", Ed. 1.0 b: 2002
VGB-R450Le VGB Guidelines for Feed Water, Boiler Water and Steam Quality
for Power Plants / Industrial Plants
VGB-R401J VGB Guideline for the Water in Nuclear Power Plants with Light
Water
Reactors
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HTGD090486V0001G
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MA - HTGD690147V0001A -
Endoscopic Inspections of Steam Turbosets
MA - HTGD690147V0001A -
Endoscopic Inspections of Steam
Turbosets
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Revision History
Document Pages
total :
A 97-04-21, Amendment of the content, inclusion of video equipment
-
- -
(8)
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MA - HTGD690147V0001A -
Endoscopic Inspections of Steam Turbosets
Contents
1
SUBJECT ...........................................................................
................................................................129
2 POSSIBILITIES OF
USE ...............................................................................
....................................130
2.1 Steam
turbine............................................................................
............................. 130
2.2 Turbine
subassemblies .....................................................................
..................... 130
3 INTERVALS BETWEEN
INSPECTIONS........................................................................
...................131
4 INSPECTION
OPENINGS ..........................................................................
.......................................131
5 SELECTION OF THE
EQUIPMENT .........................................................................
.........................131
5.1 Rigid
equipment .........................................................................
............................ 131
5.2 Flexible
equipment..........................................................................
....................... 132
5.3 Selection and additional
equipment .......................................................................
132
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128 HTGD 693 000 V0140 A en

MA - HTGD690147V0001A
-
Turbosets
1 SUBJECT
Endoscopy is one of the methods used to assess as accurately as possible the
ac-
tual condition of the components in the turbine plant.
Information on the condition of the important, functional and safety-

relevant components of a turbine plant considerably assists in
determining
the overhaul measures and the overhaul dates for the different plant
com-
ponents.
Monitoring criteria, such as checking the smooth running, pressure curve in
the tur-
bine, flow rates, output etc. are operating values that can be measured and
com-
pared with previously recorded data.
Endoscopy, on the other hand, is a visual inspection; its

significance de-
pends largely on the experience and discrimination of the person
carrying
out the inspection.
It is an efficient auxiliary means for inspecting components which cannot be
exam-
ined without opening the casings.
In addition to the purely technical background endoscopy is regarded as an
effective
means of preventive maintenance. Insurance companies extend the specified
inter-
vals between turbine overhauls if endoscopic checks are carried out.
Either the power plant operator, institutes or the supplier of the plant or
subplant
carry out the endoscopic inspection.
Inspection by the supplier has the advantage of reduced

misinterpretation
because the construction of the machine and its critical elements are
well
known.
The supplier has also vast experience in comparing the conditions of similar
plants.
In the case of irregularities, corrective actions can be taken immediately.
en HTGD 693 000 V0140 A

129
2 POSSIBILITIES OF USE
2.1 Steam turbine
In the case of steam turbines, endoscopy is primarily used for checking the
blading
for:
� Residues
� Corrosion
� Defects by striking foreign matters
� Erosion due to water, solid particles
� Rubbing
� Shroud riveting, shroud welding
� Blade intermediate pieces and end pieces
� Cracks
In the case of cracks the risk of misinterpretation by inexperienced

per-
sonnel is particularly high.
Rotor and casing can, where accessible, also be checked for the above
mentioned
defects. The rotor should be examined additionally for scale!
It is recommended to document the inspected parts by photos or video in order
to
permit comparisons over a certain period of time.
It must be possible to rotate the rotor during the inspection to

permit
checking of the rotating blading over the complete circumference.
2.2 Turbine subassemblies

Beside the steam turbine, the following subassemblies can be checked:
� Condenser tubing
� Piping
� Heat exchanger equipment like feedheater, cooler etc.
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-
Turbosets
3 INTERVALS BETWEEN INSPECTIONS

The intervals between endoscopic inspections depend on the operating mode of
the
part to be inspected. These inspections are usually carried out once a year.
In the
case of disturbances the relevant component can be inspected at any time
during a
planned or unplanned shutdown.
It must be ensured, however, that the temperature of the component

to be
checked does not exceed 80�C (176�F).
Take note of the equipment manufacturers instructions.
4 INSPECTION OPENINGS
Since a few years all turbine casings are provided with openings for
endoscopic in-
spections.
There are also various possibilities to carry out endoscopic inspections on
"older"
units, e.g.:
� Balancing holes
� Withdrawing the start-up probe
� Disconnecting the equalising pipe(s)
� Pressure measuring points in live steam pipes etc.
There is also the possibility of adding inspection openings

belatedly at cer-
tain points.
Many parts and components of the plant have tapped holes for temperature and
pressure measurements which are closed off with screw plugs and can be used
for
endoscopic inspections. Here, too, openings can be added.
5 SELECTION OF THE EQUIPMENT

Either rigid or flexible equipment with its own luminous source is used for
the endo-
scopic inspections.
5.1 Rigid equipment

Advantages
� Rigid endoscopes offer an excellent picture quality and reduced loss of
light.
� The field of vision can be easily localised.
� Rigid endoscopes can be combined to obtain an endoscope of several meters.
en HTGD 693 000 V0140 A
131
Disadvantages
� The field of application is restricted because there must be a straight
line between
the inspecting person and the object, and the inspection openings must be
in the
direct area of the object.
5.2 Flexible equipment

Advantages
� Flexible endoscopes can be turned through 360�, their field of application
is only
limited by the design of the object.
Disadvantages
� The quality of the picture is not so good because of the screen, and the
loss of
light caused by the glass fibre line in the case of glass fibre endoscopes.
� The field of vision is difficult to localise because there is no straight
connection.
5.3 Selection and additional equipment

Various criteria should be considered when selecting an equipment.
A flexible endoscope with a probe length of 3 m fulfils most of the tasks.
The probe diameter of the endoscope should not exceed 12 mm because

of the inspection openings provided.
A rigid endoscope is particularly suitable for checking the heat exchanger
tubing.
The equipment must include a camera if video equipment cannot be used.
Various suppliers offer endoscopes with video equipment which has the
following
advantages:
� The inspected object can be examined simultaneously by various persons.
� The saved documentation can be viewed at any time, permitting also compari-
sons at a later date.
HTGD690147V0001A
132 HTGD 693 000 V0140 A

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MA - HTGD090269V0001F - Permissible deviations from the nominal
speed
MA - HTGD090269V0001F -
Permissible deviations from the
nominal speed
en HTGD 693 000 V0140 A 133

Revision History
Revision Content of Change Document
Pages
total :
E 97-04-24, Scope of application, re-structuring of the text -
F 05-01-19, CHAPTER 3, CHANGED PERMISSIBLE DEVIATIONS -
- - (6)
134 HTGD 693 000 V0140 A

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MA - HTGD090269V0001F - Permissible
deviations from the nominal
speed
Contents
1
PURPOSE............................................................................
..............................................................137
2 SCOPE OF
APPLICATION........................................................................
........................................137
3 PERMISSIBLE
DEVIATIONS ........................................................................
....................................138
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135
WP4140
Figures
Fig. 3-1 Permissible deviations from the nominal

speed ........................................................... 138
136 HTGD 693 000 V0140 A

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MA - HTGD090269V0001F - Permissible deviations from the
nominal
speed
1 PURPOSE
Upper and lower limits are specified for the nominal speed in order to keep
the tur-
boset on line as long as possible, thus ensuring high availability, and to
prevent over-
load in the case of deviations from the nominal speed.
Only when exceeding these limit values, the turboset is separated from the
grid and
switched to isolated operation.
2 SCOPE OF APPLICATION
Permissible deviations from the nominal speed for steam turbines driving
generators.
The limit takes into account the speed of such a turboset in load operation.
Note
For generators in continuous underfrequency operation additional limits apply
with
respect to output and terminal voltage.
The maximum possible output in the overfrequency range depends on the control
characteristic.
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3 PERMISSIBLE DEVIATIONS
The following deviations from the nominal speed are permissible:
from + 5 % to - 6 % continuously permitted
more than - 6 % permitted during 10 seconds.
See also the table in Fig. 1.
Deviation from
nominal speed Not Permitted
in %
+5
+4
+3 Continuously Permitted
+2
+1
0
Time
-1
-2
-3
Continuously Permitted
-4
-5
-6
10 Seconds Not Permitted
Fig. 3-1 Permissible deviations from the nominal speed
HTGD090269V0001F
138 HTGD 693 000 V0140 A en

MA - HTGD090440V0001H -
Permissible Deviations
of the Steam Pressures
and Temperatures from the
MA - HTGD090440V0001H -
Rated Values
en HTGD 693 000 V0140 A 139

Revision History
Document Pa-
gestotal:
G 97-04-21, Adaptation to new standards, restructuring of the text
-
H 2004-05-13, New standards in operating conditions
-
- -
(8)
140 HTGD 693 000 V0140 A

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MA - HTGD090440V0001H -
Contents
1 OPERATING
CONDITIONS ........................................................................
......................................143
1.1
Stipulation .......................................................................
....................................... 143
1.2 Scope of
application........................................................................
....................... 143
2 PERMISSIBLE PRESSURE
DEVIATIONS ........................................................................
...............143
2.1 Continuous operation, live steam

supply ............................................................... 143
2.2 Abnormal operating
conditions ........................................................................
...... 143
2.3 Reheat, secondary and third steam
supply............................................................ 143
3 PERMISSIBLE TEMPERATURE
DEVIATIONS ........................................................................
........144
3.1 Continuous
operation..........................................................................
................... 144
3.2 Secondary and third steam
supply......................................................................... 144
3.3 Abnormal operating
conditions ........................................................................
...... 144
3.4 Parallel steam
pipes..............................................................................
................. 145
3.5 LP boiler
supply ............................................................................
......................... 145
4 SPECIAL
REGULATIONS .......................................................................
..........................................145
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142 HTGD 693 000 V0140 A en

MA - HTGD090440V0001H
-
Permissible
Deviations
of the Steam
Pressures
and Temperatures
from the
1 OPERATING CONDITIONS
1.1 Stipulation
To avoid overloading of the turboset as a result of steam data that deviate
from the
rated values, the following operating conditions have been specified for the
steam
generator.
Deviations from the rated values are permitted in accordance with:
EN 60045-1: 1993 (ex IEC 60045-1: 1991)
1.2 Scope of application

Live steam pressure (PFD) and live steam temperature (tFD) as well as reheat
pres-
sure (PZUeD) and reheat temperature (tZUeD) of reheat machines.
Secondary steam pressure (PZD), third steam pressure (PDD) and
secondary/third
steam temperatures (tZD, tDD) for combined-cycle plants.
2 PERMISSIBLE PRESSURE DEVIATIONS

2.1 Continuous operation, live steam supply
In continuous operation the yearly average pressure before the main stop
valves of
the turbine shall not exceed 100 % of the rated pressure at nominal load.
Maintaining this average, the pressure may exceed this rated value by no more
than
5 % for any length of time.
2.2 Abnormal operating conditions

CAUTION
Under abnormal operating conditions the pressure may increase to 120
%
of the rated pressure as long as the aggregate duration of such
swings
does not exceed 12 hours per year of operation.
2.3 Reheat, secondary and third steam supply

The stipulations apply analogously for the pressure in the reheater,
secondary and
third steam supply pipes if the pressure changes at all steam supplies in
percents of
the appropriate rated values.
en HTGD 693 000 V0140 A
143
3 PERMISSIBLE TEMPERATURE DEVIATIONS

3.1 Continuous operation
In continuous operation the yearly average steam temperature before the main
stop
valves and intercept valves shall not exceed the rated temperature (maximum
con-
tinuous steam temperature) tFD and tZUeD. However, as long as this average is
main-
tained the temperature may deviate by 8 �K from the rated value for any
length of
time.
The same stipulations apply for the secondary and third steam supplies as
long as
the superheat before the relevant stop valves is at least 50 �K.
3.2 Secondary and third steam supply

A moisture separator with the following separation capacity is required if
the secon-
dary and third steam supplies are designed for a superheat of less than 50 �K
or if
they lie near the saturation line:
99.5 % separation of all water drops and separation of all water drops which
are lar-
ger than 20 m.
The pressure difference at maximum load shall not exceed 50 mbar.
3.3 Abnormal operating conditions

Under abnormal operating conditions the temperature at all steam supplies may
ex-
ceed the rated temperature as follows:
up to 14 �K during 400 hours per year of operation
up to 28 �K during 80 hours per year of operation
The temperature may exceed the rated temperature by 14 �K - 28 �K in isolated
cases and for not more than 15 minutes each time.
CAUTION
Under no circumstances may the temperature exceed the rated tempera-
ture by more than 28 �K.
144 HTGD 693 000 V0140 A

en
MA - HTGD090440V0001H
-
Permissible
Deviations
of the Steam
Pressures
and Temperatures
from the
3.4 Parallel steam pipes

The steam temperatures in two or more parallel supply pipes to a turbine may
not
differ by more than 17 �K. In case of disturbances a difference of 28 �K is
permitted
for a maximum of 15 minutes per 4 hours of operating time. The steam
temperature
in the hottest pipe may not exceed the maximum values specified in the
previous
section.
If the steam generator has two or more separate steam outlets with separate
tem-
perature controls, ALSTOM demands an effective mixing duct so that the steam
temperatures at the turbine inlets do not differ by more than 17 �K even in
case of a
failure of one of the temperature controls.
The boiler control must be able to prevent the average temperature gradient
from
exceeding 200 �K/h. Maintaining this gradient, temperature swings of 50 �K
(maxi-
mum) every 15 minutes are permitted. These requirements must be met by live
and
reheat steam pipes.
3.5 LP boiler supply

If the secondary or third steam is led directly from the LP boiler drum to
the turbine
(superheat of less or equal 50 �K possible), major temperature changes or
swings
are not permitted (water hammers). The temperature deviations mentioned in
sec-
tions 3.1 to 3.3 may not be exceeded.
Note
If the temperature decreases by more than 10 �K below the rated
value,
the relevant steam supply must be switched off.
4 SPECIAL REGULATIONS
If greater pressure and temperature deviations are required, ALSTOM must be
con-
sulted.
en HTGD 693 000 V0140 A

145
Blank Page
HTGD090440V0001H
146 HTGD 693 000 V0140 A en

MA - HTGD090185V9000A -
Insulation mats on
steam turbines
MA - HTGD090185V9000A -
Insulation mats on
steam turbines
en HTGD 693 000 V0140 A 147

Revision History
Revision Contents of the revision Total
document
pages:
A 04-08-09, re-structuring of the text 12
- - (10)
148 HTGD 693 000 V0140 A

en
MA - HTGD090185V9000A -
Insulation mats on
steam turbines
Contents
1
PURPOSE............................................................................
..............................................................151
2
STRUCTURE .........................................................................
............................................................151
3 DELIVERY
INSTRUCTIONS ......................................................................
.......................................151
4 NOTES ON INSULATION
WORK...............................................................................
.......................152
4.1 Assembly
conditions ........................................................................
...................... 152
4.2 Working
instructions.......................................................................
........................ 152
5 FITTING THE
INSULATION ........................................................................
......................................153
5.1 Preparing for assembly of the insulation

mats ....................................................... 153
5.2 Fitting the insulation
mats ..............................................................................
........ 153
5.3 Fitting insulation mats with metal
cladding............................................................. 154
5.4 Inspection after assembly of the insulation
mats ................................................... 155
5.5 Covering the insulation
mats...............................................................................
... 155
6 FINAL
INSPECTION ........................................................................
..................................................156
7 ACCEPTANCE TESTING OF THE
INSULATION ........................................................................
.....156
en HTGD 693 000 V0140 A

149
Pipe insulation
Drawing of turbine insulation
150 HTGD 693 000 V0140 A en

MA - HTGD090185V9000A
-
Insulation
mats on
steam
turbines
1 PURPOSE
The turbine insulation attenuates the thermal flow between the hot surfaces
and the
surroundings. It prevents excessive heat loss on all parts of the plant which
carry
steam or hot gas condensate, and also provides protection from radiation and
con-
tact.
Furthermore, when the housing cools down, it prevents excessive thermal
tension
and the resulting asymmetrical distortion.
2 STRUCTURE
The insulating material and the method of installing it are chosen according
to the in-
structions and specifications of the insulation supplier.
The insulating materials used must be compatible with the materials of the
housing
and piping. Insulating material which contains halogens or halogen salts may
not be
used on stainless piping or machine parts.
The insulation must be protected with cladding on machines erected outside.
Note
Asbestos, material containing asbestos, PVC and polyurethane
insulat-
ing materials are prohibited.
If insulating material containing asbestos is found or suspected,
all work
must stop and the assembly managers notified.
The reusable, molded insulation sections known as mats or mattresses have the
ad-
vantage that less dirt and dust is generated during overhauls. The insulation
does
not need to be dried, which would extend the duration of the overhaul.
3 DELIVERY INSTRUCTIONS
The insulation company must supply all the thermal insulation for the turbine,
the live
steam and waste steam valves, including fastening material, and protective
covering,
and must fit the insulation. ALSTOM supplies the turbine insulation drawing in
the
tendering stage and when issuing the order.
Note
The complete customer documentation of the insulation company is
part
of the delivery scope and must be enclosed with the insulating
ma-
terial.
The selection of insulating material and the calculation of insulation
thicknesses is
the sole responsibility of the insulation company. Any information on
insulation thick-
nesses contained in the turbine insulation drawing supplied by ALSTOM is for
inter-
en HTGD 693 000 V0140 A

151
nal information only and is not binding for the insulation company. An
ambient tem-
perature of 30�C can be assumed for the design of the insulation.
The insulation thickness must be selected so that the temperature difference
be-
tween the surrounding air and the insulation surface is no more than 20�C on
plants
with cladding and 25�C on plants without cladding.
All molded insulation sections must be permanently labeled with their
location of in-
stallation and identification number in case they need to be replaced.
The insulation may only be fitted by authorized assembly staff of the
insulation com-
pany, who will do all the necessary work themselves.
Note
Notification of the selected insulation thicknesses, the material
and the
selection of fitting method must be given in writing to the
relevant
engineering department at ALSTOM.
Care should always be taken to prevent molded insulation sections
from
becoming damp, and that their outer shells should not be
damaged
when assembling and removing them.
Molded insulation sections in storage must be kept dry and
covered to
protect them against dirt. Avoid stacking the molded
sections.
4 NOTES ON INSULATION WORK

4.1 Assembly conditions
The following must be ensured before starting the work:
� The turbine, valves and piping must be closed, free of dirt, cold and
protected
from weathering and moisture.
� The turbine and its installed valves and steam pipes must be set up so that
all the
surfaces to be insulated are freely accessible. All safety regulations for
scaffold
construction must be obeyed.
� The customer documentation, including the identification data on the
insulation
material, the mounting and cladding material as well as fitting
instructions, must
be available.
4.2 Working instructions

Proper and smooth initial assembly requires the presence of a supervisor from
the
insulation company.
Assembly work may only be carried out by qualified assembly staff.
Standard insulation tools are a precondition for fitting the insulation
material.
152 HTGD 693 000 V0140 A
en
MA -
HTGD090185V9000A -
Insulation
mats on
steam
turbines
To ensure that all insulation tasks are carried out precisely, the customer
documen-
tation must be read and fully adhered to.
Any adaptations to the design due to assembly conditions must be made by the
as-
sembly staff on site.
5 FITTING THE INSULATION

5.1 Preparing for assembly of the insulation mats
The number of retention pins depends on the number of cast fittings or
threads. If the
insulation supplier requires additional fastenings, he must contact ALSTOM.
Welding work on turbine housings, valves or piping may only be carried out at
the in-
tended points. Direct welding on turbine housings, valves or piping is
prohibited.
ALSTOM is responsible for drilling holes in the existing cast fittings and
for attaching
welding discs. The insulation supplier provides the retention pins.
The mountings for insulation mats must be fitted so that the pins of the
joint flange
bolts can be removed without removing the mountings.
The fastening accessories used for assembly such as washers, pins, clips,
hooks
and wire must be made of stainless material.
Bolts on flanges must be protected with heat-resistant aluminum foil or with
sheet
metal covers.
5.2 Fitting the insulation mats

The manufacturer can decide how the insulation mats are designed. Single-or
multi-
layer mats are permitted.
Each insulation mat must be made as large as possible, provided the weight
does
not exceed 25 kg.
Note
The specific instructions for the product must be read for safety
precau-
tions when handling insulation and fibrous materials and any
help
measures.
The numbered molded insulation sections may only be fitted to the
cor-
respondingly marked position fields. They may not be fitted
on other
parts of the machine.
The following points should be observed during assembly:
� Fit the insulation mats so that there are no hollow spaces.
en HTGD 693 000 V0140 A
153
� With single-layer insulation, the insulation mats should be designed so

that they
overlap. The sides should not have a 90� angle to the surface of the mat,
but a
45� or 60� angle. In this way, air pockets can be prevented.
� With dual or multiple-layer insulation, the edges must overlap.
� The mats must be laid so that no water can collect. Therefore, the
separating
point should be at the bottom of the housing.
� Mats subject to mechanical strain or which occasionally have to be removed,
for
example those near the turbine valves, must be reinforced with a stainless
wire
mesh.
� The insulation mats must be fastened so that no hollow spaces can form,
espe-
cially in the lower parts of the housing. If there are any hollow spaces
despite this,
they must be filled with loose insulating wool or special mats.
� In parts of the insulation the mats must be laid so that they can be easily
removed
to allow occasional servicing work. This applies to the mats around the
joint
flanges, the flanges to the inflow, outflow, overflow, tapping and
extraction pipes,
the instrumentation and the balancing holes.
� Protruding mounting bolts must be shortened to the required length.
� When mounting the mats, the thermal expansion of the turbines must be taken
into account. This is especially important around the bearing blocks.
Note
When insulating the faces of the turbine, note that during every
operat-
ing phase there must be a minimum gap of 25mm between the in-
sulation and the neighboring bearing housings.
The air circulation allowed by the gap diverts any leaks from the shaft seals
and
cools the bearing blocks. In addition, the mats must be fitted so that the
bearing
block covers can be removed without damaging the insulation.
� The turbine insulation must be designed so that the thickness of the
insulation is
symmetrical to the central axis. The lower section of the turbine housing
must be
25% better insulated than the upper section. This requires either thicker
insulation
or better quality insulation. Where there is restricted space, higher
quality insula-
tion is preferable in order to allow sufficient air circulation.
� On inflow and overflow piping, the insulation must be fitted so that only a
small
amount of insulation has to be removed in order to disconnect the pipe
flanges.
The suspension points of the pipes must also be easily accessible.
� Any insulation contaminated with oil, solvent or rust remover must be
replaced.
5.3 Fitting insulation mats with metal cladding
The insulation for inflow and overflow pipes can have metal cladding. For
mainte-
nance work on flange bolts and suspension points, the insulation must be
designed
154 HTGD 693 000 V0140 A

en
MA -
HTGD090185V9000A -
Insulation
mats on
steam
turbines
according to the same criteria as for other mat insulation. After the
insulation work is
complete, it no longer has to be covered with an impermeable cloth.
Note
For insulation mats with metal cladding, see the instructions on
pipe in-
sulation.
5.4 Inspection after assembly of the insulation mats

There may be no gaps between the molded insulation sections.
The molded insulation sections must touch the bottom of the housing.
The molded insulation sections must be fitted so that no great disassembly is
re-
quired for overhaul work.
All molded insulation sections must be marked so that they can be easily
refitted in
the right place after being removed.
5.5 Covering the insulation mats

After all the insulation work on the turbine, valves and steam pipes has been
com-
pleted, the entire insulation must be covered with an impermeable tarpaulin.
The tarpaulin protects the insulation mats from weathering, dirt, dust, water
and oil.
Absolutely no fluid may penetrate the cover and get into the insulation mats.
After the covering work is finished, the work location must be thoroughly
cleaned of
all material residue.
en HTGD 693 000 V0140 A

155
6 FINAL INSPECTION
The turbine may only be put into operation after ALSTOM has inspected the
insula-
tion. Any defects must be rectified by the insulation company immediately.
The same
goes for reinsulation after disassembly.
The following must be ensured:
� The insulation must be completely fitted. The machine may not be started
with in-
completely fitted insulation.
� The insulation mats must be covered with an impermeable tarpaulin.
� Moving machine parts such as sliding elements and spindles must be
absolutely
free of pieces of insulation material or other dirt.
� The insulation work is only ended after a careful final inspection.
� After final cleaning, the scaffolding must be carefully removed.
The conditions are now in place to start the turbine and perform acceptance
testing
on the insulation.
7 ACCEPTANCE TESTING OF THE INSULATION

Acceptance takes the form of a t measurement, where the temperature
difference
between the surface of the insulation and the surrounding air is measured at
station-
ary full load.
10 to 15 measurements are taken at various points on the surface of the
turbine in-
sulation. The surrounding air is measured level with the split plane,
approximately a
meter away from the turbine. The temperature differences must be within the
range
stated in chapter 3.
The maximum temperature difference on the piping systems is 20�C.
HTGD090185V9000A
156 HTGD 693 000 V0140 A

en
MA - HTGD090185V9001A -
Spray insulation on
steam turbines
MA - HTGD090185V9001A -
Spray insulation on
steam turbines
en HTGD 693 000 V0140 A 157

Revision History
document
pages:
A 04-08-09, re-structuring of the text 12
- - (12)
158 HTGD 693 000 V0140 A

en
MA - HTGD090185V9001A -
Spray insulation on
steam turbines
Contents
1
PURPOSE............................................................................
..............................................................161
2
STRUCTURE .........................................................................
............................................................161
3 DELIVERY
INSTRUCTIONS ......................................................................
.......................................161
WORK...............................................................................
.......................162
4.1
Preconditions .....................................................................
.................................... 162
4.2 Working
instructions.......................................................................
........................ 162
5 EXECUTION OF INSULATION
WORK ..............................................................................
...............163
5.1 Preparations for spray

insulation ........................................................................
... 163
5.2 Applying spray insulation on turbines and
valves .................................................. 163
5.3 Insulating the inflow
pipes..............................................................................
........ 164
5.3.1 Execution as spray
insulation.................................................................... 164
5.3.2 Execution as molded
insulation................................................................. 165
5.4 Insulating the overflow
pipes..............................................................................
.... 165
5.5 Cleaning during insulation
work .............................................................................
165
6 STARTING THE
TURBINE ...........................................................................
.....................................166
INSULATION ........................................................................
.....166
8 APPLYING THE HARD
COATING ...........................................................................
.........................167
9 FINAL
INSPECTION ........................................................................
..................................................167
en HTGD 693 000 V0140 A

159
Pipe insulation
160 HTGD 693 000 V0140 A en

MA - HTGD090185V9001A
-
Spray
insulation on
steam
turbines
1 PURPOSE
The turbine insulation attenuates the thermal flow between the hot surfaces
and the
surroundings. It prevents excessive heat loss on all parts of the plant which
carry
steam or hot gas condensate, and also provides protection from radiation and
con-
tact.
Furthermore, when the housing cools down, it prevents excessive thermal
tension
and the resulting asymmetrical distortion.
2 STRUCTURE
to the in-
housing
and piping. Insulating material which contains halogens or halogen salts may
not be
used on stainless piping or machine parts.
The insulation must be protected with cladding on machines erected outside.
Note
insulating
materials are prohibited.
If insulating material containing asbestos is found or suspected, all
work
The insulation company must supply all the thermal insulation for the
turboset, in-
cluding the fastening material, hard coating and protective paint, and must
fit the in-
sulation. ALSTOM supplies the turbine insulation drawing in the tendering
stage and
when issuing the order.
Note
The complete customer documentation of the insulation company is part
of
the delivery scope and must be enclosed with the insulating material.
thicknesses is
insulation thick-
inter-
nal information only and is not binding for the insulation company. An ambient
tem-
perature of 30�C can be assumed for the design of the insulation.
en HTGD 693 000 V0140 A

161

be-
tween the surrounding air and the insulation surface is no more than 20�C on
plants
with cladding and 25�C on plants without cladding.
insulation com-
Note
Notification of the selected insulation thicknesses, the material
and the se-
lection of fitting method must be given in writing to the relevant
engineer-
ing department at ALSTOM.
Spray insulation may not be used for nuclear plants with boiling
water re-
actors, since waste requires special disposal.

4.1 Preconditions
� The turbine, valves and piping must be closed, free of dirt, cold and
protected
from weathering and moisture.
� The turbine and its installed valves and steam pipes must be set up so that
all the
scaffold
insulation
instructions, must
be available.

documen-
as-
162 HTGD 693 000 V0140 A

en
MA -
HTGD090185V9001A -
Spray
insulation on
steam
turbines
5 EXECUTION OF INSULATION WORK

5.1 Preparations for spray insulation
The number of retention pins depends on the number of cast fittings or
threads. If the
insulation supplier requires additional fastenings, he must contact ALSTOM.
Welding work on turbine housings, valves or piping may only be carried out at
the in-
tended points. Direct welding on turbine housings, valves or piping is
prohibited.
ALSTOM is responsible for drilling holes in the existing cast fittings and
for attaching
welding discs. The insulation supplier provides the retention pins.
The mountings for spray insulation must be fitted so that the pins of the
joint flange
bolts can be removed without removing the mountings.
The fastening accessories used for assembly such as washers, pins, clips,
hooks
and wire must be made of stainless material.
sheet
metal covers.
Before starting the application of the spray insulation on the turbine
housing and
valve housings, all sensitive parts must be covered with plastic foil. This
applies to:
bearing blocks, sliding elements, turbine rotors, valve stems, parts of the
instrumen-
tation and parts of the plant around the lower section of the turbine. As
little dust as
possible should accrue.
5.2 Applying spray insulation on turbines and valves

Note
precau-
tions when handling insulation and fibrous materials and any help
meas-
ures.
The following points should be observed during insulation work:
� When injecting the insulation, always make sure that as little water as
possible is
used.
� When applying spray insulation between the retaining pins, the insulation
must be
continuously fixed using self-locking blocking disks. This ensures that the
insula-
tion is in direct contact with the housing, thus preventing it sagging
towards the
lower section. The spray insulation should be reinforced with layers of
wire mesh.
� The turbine insulation must be designed so that the thickness of the
insulation is
symmetrical to the central axis. The lower section of the turbine housing
must be
25% better insulated than the upper section. This requires either thicker
insulation
en HTGD 693 000 V0140 A

163
or better quality insulation. Where there is restricted space, higher

quality insula-
tion is preferable in order to allow sufficient air circulation.
� Deviations in the insulation thickness from -10% to +20% in order to
adapt the
contour for joints are allowed, if they are symmetrical to the central
axis of the
housing.
� Insulation around the instrumentation, balancing hole cover, temperature
probe
and flanges to the overflow pipes must be fitted so that it can be
removed. At
these points, molded sections made of insulating wool and aluminum
cladding
should be used instead of spray insulation. The edges of the cladding
should be
fitted so that splashing or dripping oil cannot penetrate the insulation.
� When applying the spray insulation, the thermal expansion of the turbines
must
be taken into account. This is especially important around the bearing
blocks.
Note
When insulating the faces of the turbine, note that during every
operating
phase there must be a minimum gap of 25mm between the insulation
and
the neighboring bearing housings.
The air circulation allowed by the gap diverts any leaks from the shaft
seals and
cools the bearing blocks. In addition, the insulation must be applied so
that the bear-
ing block covers can be removed without damaging the insulation.
� Around the joint flanges of the of turbine, the insulation should be
applied and fas-
tened so that it can be removed without damaging the entire insulation.
replaced.
� When application of the insulation has finished, it must be left for at
least 7 days
to dry.
5.3 Insulating the inflow pipes

5.3.1 Execution as spray insulation
Like the turbine and the valves, inflow pipes can be insulated with foam,
then given a
hard coating and protective paint. The insulation must be fitted so that
only a small
amount of insulation has to be removed in order to disconnect the pipe
flanges. The
suspension points of the pipes must be easily accessible.
When application of the insulation has finished, it must be left for at
least 7 days to
dry.
164 HTGD 693 000 V0140 A
en
MA -
HTGD090185V9001A -
Spray
insulation on
steam
turbines
5.3.2 Execution as molded insulation

Insulation using metal-clad mats is also permissible for inflow pipes.
Note
For insulation mats on inflow pipes, see the instructions on pipe
insulation.
5.4 Insulating the overflow pipes

When insulating the overflow pipes to the low-pressure turbine, either
molded mats
of mineral wool or cylindrical molded pieces can be used. The mats are
reinforced on
one side with galvanized, hexagonal wire mesh. The insulation must be
fitted so that
only a small amount of insulation has to be removed in order to disconnect
the pipe
flanges. The suspension points of the pipes must be easily accessible.
Note
For insulation work on overflow pipes, see the instructions on
pipe insula-
tion.
5.5 Cleaning during insulation work

Depending on the working stage, the working area and all the machine parts
below it
must be cleaned. Especially on rotating or moving parts such as rotors,
sliding ele-
ments and valve stems, special care must be taken to ensure that they are
free of
insulation residue or other dirt.
en HTGD 693 000 V0140 A

165
6 STARTING THE TURBINE

The turbine may only be put into operation after ALSTOM has inspected the
insula-
tion. Any defects must be rectified by the insulation company immediately.
The same
goes for reinsulation after disassembly.
On parts with spray insulation, the hard coating may only be applied later.
� Check that all parts of the spray insulation are dry. Dry insulation only
becomes
hand-hot, while wet insulation normally becomes hot to very hot.
CAUTION
Due to the risk of uncontrolled housing deformation, it is not
permitted to
start up steam turbines while the insulation is still wet or damp.
� The insulation must be completely fitted. The machine may not be started
with in-
completely fitted insulation.
� Moving machine parts such as rotors, sliding elements and spindles must be
ab-
solutely free of pieces of insulation material or other dirt.
After cleaning, the conditions are in place to start the turbine and perform
accep-
tance testing on the insulation.

Acceptance takes the form of a t measurement, where the temperature
difference
between the surface of the insulation and the surrounding air is measured at
station-
ary full load.
10 to 15 measurements are taken at various points on the surface of the
insulation.
The surrounding air is measured level with the split plane, approximately a
meter
away from the turbine. The temperature differences must be within the range
stated
in chapter 3.
166 HTGD 693 000 V0140 A

en
MA -
HTGD090185V9001A -
Spray
insulation on
steam
turbines
8 APPLYING THE HARD COATING

After around 7 days of operation and acceptance of the insulation by ALSTOM,
the
hard coating may be applied to the turbine and the valves.
On the spray insulation, which may be reinforced with galvanized 13 to 16mm
steel
wire if necessary, the approximately 5mm thick hard coating can be applied
using a
trowel.
While the hard coating is being applied, it can be divided into sections with
joint tape
or by including expanding joints. The size of each section should be chosen so
that
no cracks are caused by expansion during operation.
After 10 days of operation the hard coating is dry. All joints must be sealed
with per-
manently elastic grouting. Any cracks in the hard coating are sanded out and
filled
with grouting.
After this, an oil-resistant, waterproof coat of protective paint is applied,
which meets
the latest fire prevention standards.
9 FINAL INSPECTION
During the final test, the following must be ensured:
� The applied hard coating is complete and dried out.
� All joints in the hard coating are sealed with grouting. Any cracks in the
hard coat-
ing are sanded out and filled with grouting.
� The hard coating is completely covered in protective paint.
� Moving machine parts such as rotors, sliding elements and spindles must be
ab-
solutely free of pieces of insulation material or other dirt.
� The insulation work, hard coating and painting is only ended after a careful
final
inspection.
en HTGD 693 000 V0140 A

167
Blank Page
HTGD090185V9001A
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MA - HTGD090185V9002 -
Pipe insulation
MA - HTGD090185V9002 -
Pipe insulation
en HTGD 693 000 V0140 A 169

Revision History
document
pages:
- - (12)
170 HTGD 693 000 V0140 A

en
MA - HTGD090185V9002 -
Pipe insulation
Contents
1
PURPOSE............................................................................
..............................................................173
2
STRUCTURE .........................................................................
............................................................173
3 DELIVERY
INSTRUCTIONS ......................................................................
.......................................173
4 REQUIREMENTS FOR INSULATION
MATERIAL...........................................................................
.174
WORK...............................................................................
.......................175
5.1 Assembly
conditions ........................................................................
...................... 175
5.2 Working
instructions.......................................................................
........................ 175
6 FITTING THE
INSULATION ........................................................................
......................................175
6.1 Preparing for assembly of the molded insulation

sections..................................... 175
6.2 Fitting the molded insulation
sections .................................................................... 176
CLADDING...........................................................................
................177
7.1 Material
specification .....................................................................
........................ 177
7.1.1 Aluminum sheet
cladding ..........................................................................
177
7.1.2 Optional galvanized sheet steel
cladding .................................................. 177
7.2 Fitting on straight
pipes..............................................................................
............ 177
7.3 Fitting on pipe
bends..............................................................................
................ 178
7.4 Fitting at measuring points and pipe suspension
points ........................................ 178
7.5 Mounting on fittings and expansion
joints .............................................................. 178
7.6 Cleaning after assembly of the insulation
cladding................................................ 178
8 FINAL
INSPECTION ........................................................................
..................................................179
INSULATION ........................................................................
.....179
en HTGD 693 000 V0140 A

171
172 HTGD 693 000 V0140 A en

MA -
HTGD090185V9002 -
Pipe
insulation
1 PURPOSE
The insulation on the internal steam pipes and steam turbine fittings
attenuates the
thermal flow between the hot surfaces and the surroundings. It prevents
excessive
heat loss on all piping which carries steam or hot gas condensate, and also
provides
protection from radiation and contact.
2 STRUCTURE
to the in-
piping.
Note
insulat-
ing materials are prohibited.
If insulating material containing asbestos is found or suspected,
all work
The insulation company must supply all the thermal insulation for the steam
pipes
and fittings, including cladding, fastening material, and must fit the
insulation and
cladding. ALSTOM supplies the turbine insulation drawing in the tendering
stage and
when issuing the order.
Note
The complete customer documentation of the insulation company is
part
of the delivery scope and must be enclosed with the insulating
ma-
terial.
thicknesses is
insulation thick-
inter-
nal information only and is not binding for the insulation company. All steam
pipes or
plant parts must be insulated if they are exposed to temperatures above 60�C.
This
also includes pipes or fittings which only reach these temperatures in a
certain oper-
ating condition. An ambient temperature of 30�C can be assumed for the design
of
the insulation.
be-
tween the surrounding air and the insulation surface is no more than 20�C.
Gener-
ally, the minimum insulation thickness for hot and cold insulation is 30 mm.
en HTGD 693 000 V0140 A

173

insulation com-
Note
Notification of the selected insulation thicknesses, the
material and the
selection of fitting method must be given in writing to
the relevant
engineering department at ALSTOM.
Care should always be taken to prevent molded insulation
sections from
becoming damp, and that their outer shells should not be
damaged
when assembling and removing them.
Molded insulation sections in storage must be kept dry and
covered to
protect them against dirt.
4 REQUIREMENTS FOR INSULATION MATERIAL

Depending on the situation, mineral wool in the form of mats or cylindrical
molds is
used. The molded insulation sections are reinforced on one side with
galvanized,
hexagonal wire mesh.
The insulating material must have good mechanical properties, be non-
flammable
and free of materials which might cause corrosion on the surfaces to be
insulated.
If mountings or disks are required for the insulation, then black steel can
be used for
pipe temperatures below 400�C and chrome-molybdenum steel is required for
tem-
peratures above 400�C.
Stainless steel strips or wires are used for fastening the molded insulation
sections.
Depending on the application, the following strip and wire cross-sections are
used:
- Steel strip, stainless 0.4x13mm for pipes and cylinders up to 900mm
- Steel strip, stainless 0.4x19mm for pipes and cylinders over 900mm
- Steel wire, stainless 0.9mm for pipes up to 300mm
- Steel wire, stainless 1.2mm for pipes from 350mm to 450mm
174 HTGD 693 000 V0140 A

en
MA -
HTGD090185V9002 -
Pipe
insulation

5.1 Assembly conditions
� The surfaces to be insulated must be closed, free of dirt, cold and
protected from
weathering and moisture.
� Pipes painted to protect them against corrosion must be cleaned so that the
cor-
rosion protection is still intact afterwards.
� The turbine with its internal steam pipes and fittings must be set up so
that all the
scaffold
insulation
instructions, must
be available.

Standard insulation tools are a precondition for fitting the insulation
material.
documen-
as-

6.1 Preparing for assembly of the molded insulation sections
On systems which require a pressure test, insulation work on flanges, bolted
connec-
tions and fittings can only be carried out after the pressure test.
If the insulation is more than 60mm thick, spacers must be fitted at
distances of no
more than 950mm. This ensures even, round insulation.
On vertical pipes, prepared mountings must be fitted every 2 to 4 meters.
Direct welding of mountings on piping or fitting is prohibited. Make sure no
unwanted
heat transfer is caused.
Black steel is sufficient for mountings or disks exposed to pipe temperatures
up to
400�C, but above that, chrome-molybdenum steel must be used.
en HTGD 693 000 V0140 A

175
Stainless steel wire is used to fasten molded insulation sections on pipes or

cylinders
up to 450mm, and a stainless steel strip is used for diameters above 500mm.
sheet
metal covers.
6.2 Fitting the molded insulation sections

The manufacturer can decide how the molded insulation sections are designed.
Note
precau-
tions when handling insulation and fibrous materials and any
help
measures.
The following points should be observed during assembly:
� Molded insulation sections must be cut exactly to size and fitted without
gaps. If
gaps are unavoidable, they must be filled with mineral wool of the same
quality.
� Protruding molded insulation parts can be prevented if they are trimmed to
the
correct size.
� Bends in pipes must be insulated with molded sections just like straight
pipes.
Loose insulation is not permitted.
� The prescribed insulation thickness along the entire pipe or fitting may
not deviate
by more than 10 mm either way.
� Insulation up to 120 mm thick is fitted as a single layer.
� Insulation thicker than 120 mm requires two layers. The molded sections in
the
second layer must be fitted with an offset, so that the joins are not above
each
other.
� Openings around pipe mountings must be carefully cut out.
� With horizontal pipes, the join of the insulation must be at the bottom.
� All joints in the insulation must be connected with 0.7mm thick stainless
steel
wire, with at least 15 pins per meter.
replaced.
� Thoroughly clean the work location of all material residue.
176 HTGD 693 000 V0140 A

en
MA -
HTGD090185V9002 -
Pipe insulation
7 FITTING THE INSULATION CLADDING

7.1 Material specification
7.1.1 Aluminum sheet cladding
To protect the insulation, cladding made of flat sheet aluminum (Al Mg
Mn0.8) or a
similar alloy is attached, and fastened with stainless steel strips.
Depending on the
application, the following strip cross-sections and sheet thicknesses are
used:
- Steel strip, stainless 0.4x13mm for pipes and cylinders up to
900mm
- Steel strip, stainless 0.4x19mm for pipes and cylinders over 900mm
- Aluminum sheet 0.6mm for pipes up to 200mm
- Aluminum sheet 0.8mm for pipes from 200mm to 600mm
- Aluminum sheet 1.0mm for pipes above 600mm
- Aluminum sheet 1.2mm for surfaces subject to strain and
for
horizontally fitted valves
7.1.2 Optional galvanized sheet steel cladding

To protect the insulation, cladding made of flat sheet steel galvanized on
both sides
is attached, and fastened with stainless steel strips. Depending on the
application,
the following strip cross-sections and sheet thicknesses are used:
- Steel strip, stainless 0.4x13 mm for pipes and cylinders up to
900mm
- Steel strip, stainless 0.4x19 mm for pipes and cylinders over 900mm
- Sheet steel, galvanized 0.75 mm for pipes up to 200mm
- Sheet steel, galvanized 0.88 mm for pipes from 200mm to 600mm
- Sheet steel, galvanized 1.00 mm for pipes over 600mm
- Sheet steel, galvanized 1.50 mm for pipes subject to heavy strain
7.2 Fitting on straight pipes

Even, circular sheets should be held together at spaces of 150mm with
stainless,
self-tapping metal screws. Adjacent cladding components must be connected
using
suitable reinforcing sections of 4 to 12mm thickness.
The joins around the cladding sections should have a flanged edging, and
overlap by
at least 50mm. The long edges should also be flanged and overlap by the
same
amount. The insulation sheets must be fitted so that no water can collect.
When
necessary, edging can be sealed with putty.
Neighboring sheets should overlap to cater for expansion. On vertical
pipes, the ex-
pansion joints should be fitted on the support rings, and the upper sheet
should slide
into the lower one, so that water can flow off.
en HTGD 693 000 V0140 A
177
7.3 Fitting on pipe bends

Pipe bends are manufactured from individually cut sheet metal sections,
flanged at
the ends and fastened with metal screws around the circumference. The
individual
segments must be carefully manufactured. Especially for hot steam pipes, the
over-
lap of the segments must be designed so that they can cater for pipe
expansion.
7.4 Fitting at measuring points and pipe suspension points

At the measuring points on the pipe, the insulation cladding must be cut
neatly with
enough space to carry out maintenance without taking off the entire cladding.
The
openings around the measuring points are sealed with a funnel-shaped metal
collar.
The openings around the pipe suspension points are closed with flanged
plates.
7.5 Mounting on fittings and expansion joints

Flanged valves and other fittings must be insulated with easily removable,
two-or
more-part boxes consisting of insulation wool and aluminum cladding. The
boxes
must be manufactured so that the bolts on the flanges of the fitting can be
loosened
and removed after the insulation is taken off. On welded fittings, the
removable clad-
ding must be approximately twice as thick above the welded joint. Valves with
an
operating temperature above 120�C must be insulated above the adapter.
The function of axial or radial expansion joints fitted in pipes may not be
impaired in
any way by insulation and metal cladding.
The cladding boxes are held together with spring clips. The weight limit for
each in-
sulation element is 25kg.
7.6 Cleaning after assembly of the insulation cladding

After work on cladding for the pipes and fittings is finished, the work
location must be
thoroughly cleaned of material residue for the final inspection.
178 HTGD 693 000 V0140 A

en
MA -
HTGD090185V9002 -
Pipe
insulation
8 FINAL INSPECTION
The turbine and its internal pipes and fittings may only be put into operation
after
ALSTOM has inspected the insulation. Any defects must be rectified by the
insula-
tion company immediately. The same goes for reinsulation after disassembly.
� The insulation and cladding must be completely fitted.
� All equipment must be completely free of pieces of insulation material or
other
dirt.
� The insulation and cladding work is only ended after a careful final
inspection.
The conditions are now in place to start the turbine and perform acceptance
testing
on the insulation.

Acceptance of the insulation on the internal steam pipes and fittings, as well
as the
turbine, takes the form of a t measurement, where the temperature difference
be-
tween the surface of the insulation and the surrounding air is measured at
stationary
full load.
Measurements are taken at various points on the surface of the insulation. The
sur-
rounding air is measured level with the split plane, approximately a meter
away from
the pipe. The specified temperature differences can be found in the relevant
turbine
insulation instructions (for mat or foam insulation).
en HTGD 693 000 V0140 A

179
Blank Page
HTGD090185V9002
180 HTGD 693 000 V0140 A en

MA - HTGD090387V9000 -
Balancing of the
Turbine Rotors
MA - HTGD090387V9000 -
Balancing of the
Turbine Rotors
en HTGD 693 000 V0140 A 181

Revision History
total :
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182 HTGD 693 000 V0140 A en

MA - HTGD090387V9000 -
Balancing of the
Turbine Rotors
Contents
1
GENERAL ...........................................................................
...............................................................185
2 REBALANCING
PROCEDURE .........................................................................
................................185
2.1 Inserting and securing the balancing

weights ........................................................ 186
2.2 Inserting the balancing screws in a cold
shaft ....................................................... 186
2.3 Inserting the balancing screws in a hot
shaft ......................................................... 187
2.4 Securing the balancing
screws ............................................................................
.. 188
3 FINAL
WORK ..............................................................................
.......................................................188
4 HANDLING THE BALANCING SCREWS DURING
INSPECTIONS.................................................189
en HTGD 693 000 V0140 A

183
& WP4140
Figures
Fig. 2-1 Inserting the balancing

weights ...........................................................................
......... 186
Fig. 2-2 Inserting the balancing
screws ............................................................................
......... 187
Fig. 2-3 Securing the balancing
screws.............................................................................
........ 188
184 HTGD 693 000 V0140 A

en
MA -
HTGD090387V9000 -
Balancing
of the
Turbine
Rotors
1 GENERAL
The turbine rotors are balanced in the factory before delivery to the
customer. For
this purpose each rotor is provided with at least three balancing planes.
The balancing planes are either tapped holes for inserting balancing screws in
the
rotor end sections or trapezoidal grooves to accommodate balancing weights ap-
proximately in the middle of the rotor. In certain cases the facesides of the
rotor end
sections are provided with grooves.
The balancing planes in the middle of the rotor or the grooves in the rotor
end sec-
tions are preferably used for balancing in the factory. The tapped holes in
the rotor
end sections are thus available for rebalancing in the plant.
Rebalancing in the plant may be necessary after initial assembly or overhauls.
The
balancing planes in the rotor end sections are accessible through openings in
the
faceside outer casing upper parts.
Special tools for inserting, fastening and caulking the balancing screws are
supplied
in the tool cabinets.
Special grease 27 is used for lubricating the tapped holes and threaded
sections of
the balancing screws.
2 REBALANCING PROCEDURE
WARNING
Automatic re-start
Oil pressure in the system could cause injury
Tag-out/Lock-out the pumps for generating the pressure in the safety system
to
prevent unexpected switching-on.
Determine the location and size of the required balancing weights with an
electronic
balancing device.
Record the fitting position and weight data of the required bal- Test
certificate
ancing weights and balancing screws in the test certificate. 1BSE 501
638
Remove the covers and seals from the balancing openings in the outer casings
and
turn the rotor into the required position.
Caution
The auxiliary oil pump and the jacking oil system must be in operation when
turning
the rotor manually.
en HTGD 693 000 V0140 A

185
2.1 Inserting and securing the balancing weights

Insert the balancing weight 3 in the rotor 1 according to Fig. 2-1 and caulk
it in the
groove 4 using a chisel.

1 Rotor 4 Groove
3 Balancing weight
Fig. 2-1 Inserting the balancing weights
2.2 Inserting the balancing screws in a cold shaft

Fit the lubricated balancing screw 2 on the screw driver 901 according to
Fig. 2-2
and secure it against dropping with a knurled screw 904 . Insert the
balancing
screw in the tapped hole of the rotor 1 using the screw driver and fasten it
with a fork
wrench.
The balancing screw can be secured according to 2.4.
186 HTGD 693 000 V0140 A

en
MA -
HTGD090387V9000 -
Balancing
of the
Turbine
Rotors
2.3 Inserting the balancing screws in a hot shaft

If the turbines are still warm from operation, exchange or insert the weights
within the
shortest time possible in order to avoid deformation or jamming of the rotor.
Proceed as follows:
� Stop and lock the rotor turning gear.
� Manually turn the rotor into a position, which is 180� opposite to the
foreseen po-
sition and leave it in this position for 5 minutes.
� Turn the rotor into the foreseen position. Insert the lubricated balancing
screw,
which has been secured with the knurled screw 904 on the screw driver 901
(see Fig. 2-2), into the provided hole and slightly tighten it.
� Turn the rotor through 180� and leave it in this position for 5 minutes so
that the
inserted balancing screw adopts the temperature of the rotor.
� Turn once more the rotor through 180�, firmly tighten the screw and secure
it ac-
cording to 2.4.
� After inserting and securing the balancing weight, manually turn the rotor
one
complete turn and immediately restart the rotor turning gear.

1 Rotor 901 Screw driver
2 Balancing screw 904 Knurled screw
Fig. 2-2 Inserting the balancing screws
en HTGD 693 000 V0140 A

187
2.4 Securing the balancing screws

Insert the caulking tool 902 in the centring bore of the balancing screw 2
according
to Fig. 2-3 and secure it by hammer blows.
It is not necessary to secure balancing weights that are inserted for
balancing test
runs. However, they must be secured after completing balancing and before
starting
commercial operation.

1 Rotor 902 Caulking tool
2 Balancing screw
Fig. 2-3 Securing the balancing screws
3 FINAL WORK
Close off pressure-tight the balancing openings in the outer casings with
covers and
seals.
Clean the tools and store them in the tool cabinet.
188 HTGD 693 000 V0140 A

en
MA - HTGD090387V9000
-
Balancing of
the
Turbine
Rotors
4 HANDLING THE BALANCING SCREWS DURING

INSPECTIONS
Remove the screwed-in balancing weights in the case of C-inspections.
Re-tap the threads of balancing weight and rotor.
Record the weight after cleaning the balancing screws.
Compare the recorded weights with the entries made in the Test
certificate
test certificate and enter the values, if necessary. 1BSE 501 638
If several balance screws are inserted in one plane along the circumferance of
the
rotor, remove and weigh the screws, and then to allow for future balancing,
replace
them with fewer number of balance screws that will add up to the same total
weight.
en HTGD 693 000 V0140 A

189
Blank Page
HTGD090387V9000
190 HTGD 693 000 V0140 A en

MA - HTGD090325V9000 -
Hydraulically Prestressed
Foundation Bolts
MA - HTGD090325V9000 -
Foundation Bolts
en HTGD 693 000 V0140 A 191

Revision History
total :
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192 HTGD 693 000 V0140 A en

MA - HTGD090325V9000 -
Foundation Bolts
Contents
1 GENERAL
NOTES..............................................................................
...............................................195
1.1
Alignment .........................................................................
...................................... 195
1.2 Lubricating the
components.........................................................................
.......... 195
2 MOUNTING THE TENSIONING
DEVICE ............................................................................
.............195
3 PRESTRESSING THE FOUNDATION
BOLTS .............................................................................
....197
4 LOOSENING THE FOUNDATION
BOLTS..............................................................................
..........197
5 FREQUENCY OF CHECKING THE FOUNDATION
BOLTS ............................................................198
en HTGD 693 000 V0140 A

193
WP4140
Figures
Fig. 1 Arrangement of the tensioning

device ............................................................................
. 196
194 HTGD 693 000 V0140 A

en
MA -
HTGD090325V9000 -
Hydraulically
Prestressed
Foundation Bolts
1 GENERAL NOTES
WARNING
Fluids, lube oil
Absorbtion, skin contact, eye contact, and swollowing while filling, using,
recovering or draining of fluids causes health problems.
Make sure the Material Safety Data Sheet(MSDS) is consulted.
Carefully follow the safety instructions.
1.1 Alignment
Prestress the foundation bolts with the hydraulic tensioning device after
aligning the
machine. If the bolts are prestressed individually, carry out this process
diagonally
and in steps. Check the alignment of the machine once again after completing
the
prestressing process.
Note
If necessary, correct the alignment and repeat the prestressing process.
See the test certificate "Shaft deflection line" for the vertical Test
certificate
bearing positions. 1BSE 501
730
1.2 Lubricating the components

Clean all parts, especially the threaded parts and contact surfaces.
Lubricate these
parts with special grease 27 before starting the prestressing process.
2 MOUNTING THE TENSIONING DEVICE

Provide the foundation bolt 1 with the support disk 3 and special nut 2
according to
Fig. 1. Tighten only manually the special nut. Make sure that the nut rests
on the disk
with its complete surface.
Note
Check the perpendicularity of the bolts to the support. The deviation may not
ex-
ceed 0.3%, i.e. 90� � 16�.
Compress the hydraulic cylinder 905 by turning the pressure piston with a
face
spanner. The bottom of the piston must be flush with the cylinder hous-ing.
en HTGD 693 000 V0140 A
195

1 Foundation bolt 904 Rollpin
2 Special nut 905 Hydraulic cylinder
3 Support disk 906 Set of seals
901 Support ring 907 Coupling adapter
902 Carrier bolt 908 Marking
903 Handle
Fig. 1 Arrangement of the tensioning device
196 HTGD 693 000 V0140 A en

MA -
HTGD090325V9000 -
Hydraulically
Prestressed
Foundation Bolts
3 PRESTRESSING THE FOUNDATION BOLTS

Connect the HP hose of the HP pump unit with the coupling adapter 907 .
Build up oil pressure at the pump until the value specified in Test
certificate
the test certificate is attained. Maintain constant this pressure. HTGD 667
259
Caution
Stop the prestressing process when the marking at the hydraulic cylinder
becomes
visible!
If this occurs, bring the hydraulic cylinder back into the original position
and retighten
the special nut 2 manually. Compress the hydraulic cylinder 905 by turning the
pressure piston with a face spanner. The bottom of the piston must be flush
with the
cylinder housing.
If several tensioning devices are attached to the same object, all tensioning
devices
must have the specified oil pressure at the end of the prestressing process.
Tighten the special nut 2 via the carrier bolt 902 and the handle 903 .
The specified oil pressure must still be available.
Decrease the oil pressure to zero by loosening the relief screw at the HP pump
unit.
Repeat the prestressing process so that the consequences of settling in the
compo-
nents to be stressed are largely eliminated.
4 LOOSENING THE FOUNDATION BOLTS

Mount the tensioning device as described above. Adjust the clearance "S" of 1
mm
to 1.5 mm. Build up oil pressure until the special nut 2 can be loosened via
the car-
rier bolt 902 and handle 903 .
Note
The clearance must be available along the complete circumference because oth-
erwise there is the risk that the hydraulic cylinder cannot be removed after
loosen-
ing.
Loosen the special nut 2 up to the stop towards the hydraulic cylinder 905 and
ro-
tate it slightly into the opposite direction. Decrease the oil pressure and
remove the
tensioning device.
Compress the hydraulic cylinder 905 by turning the pressure piston with a face
spanner. The bottom of the piston must be flush with the cylinder hous-ing.
en HTGD 693 000 V0140 A
197
5 FREQUENCY OF CHECKING THE FOUNDATION BOLTS

Check the prestress of the foundation bolts after:
� one year
� two years
� four years
� seven years
Enter the values in the test certificate and initial the certificate. Test
certificate
HTGD
667 259
HTGD090325V9000
198 HTGD 693 000 V0140 A

en
MA - HTGD090028V0004B -
Rotor Raising Device
for turbine & generator rotors
MA - HTGD090028V0004B -
en HTGD 693 000 V0140 A 199

Revision History
total :
- - (8)
200 HTGD 693 000 V0140 A en

MA - HTGD090028V0004B -
Contents
1
PURPOSE............................................................................
..............................................................203
2 RAISING THE
ROTOR .............................................................................
.........................................205
en HTGD 693 000 V0140 A

201
WP4110 & WP4140
Figures
Fig. 1 Rotor raising

device.............................................................................
............................ 204
202 HTGD 693 000 V0140 A

en
MA -
HTGD090028V0004B -
Rotor
Raising Device
for turbine &
generator rotors
1 PURPOSE
The rotor raising device is used to raise the rotor a small distance to allow
for meas-
uring the bearing clearances or to allow for dismantling and re-assembling of
the
journal bearings. To permit the lower bearing shells to be removed without
damage
to the blades or stator windings it is sufficient to raise the rotors by 0.2
to (max.) 0.3
mm.
Note
The rotor can only be moved or rotated when the raising device with sliding
plate is
used.
CAUTION
It is not advisable to raise the turbine rotors with the hoisting equipment if
the tur-
bine casing is still closed because of the risk of incorrect operation.
Fig. 1 shows the rotor raising device.
en HTGD 693 000 V0140 A

203

1 Rotor journal area 903 Threaded bar
2 Bearing pedestal 904 Hexagon Nut
901 Raising device 905 Sliding plate
902 Bracket
Fig. 1 Rotor raising device
204 HTGD 693 000 V0140 A en

MA -
HTGD090028V0004B -
Rotor
Raising Device
for turbine &
generator rotors
2 RAISING THE ROTOR

Starting point
The oil shield has been removed at the bearing pedestal 2 where the rotor will
be
raised.
To raise the rotor, put the inlay piece 901 on the rotor and rotate it under
the rotor
into the bearing pedestal, screw in the threaded bolts 903 . Put the bracket
902
over the threaded bolts and let it rest on the bearing pedestal 2, fit the
hexagon nuts
904 .
CAUTION
Do not put the raising device onto the rotor journal area.
Turn the hexagon nuts 904 uniformly and raise the rotor by 0.2 mm.
Note
Monitor the rotor raising with a dial gauge to ensure relief of the bearings.
en HTGD 693 000 V0140 A

205
Blank Page
HTGD090028V0004B
206 HTGD 693 000 V0140 A en

MA - HTGD690555V0001A -
Suspension Device
MA - HTGD690555V0001A -
Suspension Device
en HTGD 693 000 V0140 A 207

Revision History
total :
A 98-08-21, New content -
- - (8)
208 HTGD 693 000 V0140 A en

MA - HTGD690555V0001A -
Suspension Device
Contents
1 SCOPE OF
APPLICATION........................................................................
........................................211
2
APPLICATION........................................................................
............................................................211
en HTGD 693 000 V0140 A

209
WP4110 & WP4140
Figures
Fig. 1 Attaching the

device ............................................................................
............................ 211
Fig. 2 Dismantling the exhaust
cone ..............................................................................
........... 212
210 HTGD 693 000 V0140 A

en
MA - HTGD690555V0001A -
Suspension
Device
The suspension device is used for dismantling and re-mounting the bearing
casing
upper parts, bearings and shaft seal housings if a cross-over pipe is located
above
the components to be lifted.
2 APPLICATION
Attach the suspension device 901 with shackle 902 and ropes at the short part
to
the hoisting equipment according to Fig. 1 and move it over the component to
be
lifted so that the device surrounds the cross-over pipe.

1 Cross-over pipe 902 Shackle
901 Suspension device
Fig. 1 Attaching the device
en HTGD 693 000 V0140 A

211
Move the device manually into the proper position because the inclined
position of
the device impairs the fastening of loads.
The example in Fig. 2 shows the lifting out of the exhaust cone (shaft seal
housing
upper part). It is necessary to remove the bearing casing upper part before
disman-
tling the exhaust cone.

1 Cross-over pipe 901 Suspension device
2 Exhaust cone 902 Shackle
Fig. 2 Dismantling the exhaust cone
212 HTGD 693 000 V0140 A

en
MA - HTGD690555V0001A -
Suspension
Device
WARNING
Suspended Load
Load or part of load can fall down and cause injury.
Wear correct personal protective equipment, hard hat, safety boots.
Do not stand under suspended loads.
Make sure that persons not involved in the procedure are out of the danger
area.
Do not overload the lift equipment.
Use lifting points on the component.
Do not let the slings and ropes get damaged on sharp edges.
en HTGD 693 000 V0140 A

213
Blank Page
HTGD690555V0001A
214 HTGD 693 000 V0140 A en

MA - HTGD090319V9000 -
Rotor Lifting Device
MA - HTGD090319V9000 -
en HTGD 693 000 V0140 A 215

Revision History
total :
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MA - HTGD090319V9000 -
Contents
1
PURPOSE............................................................................
..............................................................219
2 LIFTING OUT THE
ROTOR..............................................................................
.................................220
2.1 Check before lifting out the

rotor............................................................................
220
2.2 Lifting out the
rotor .............................................................................
.................... 220
3 LIFTING IN THE
ROTOR..............................................................................
.....................................221
3.1 Lifting in the

rotor .............................................................................
...................... 221
3.2 Check measurements after lifting in the
rotor ........................................................ 222
en HTGD 693 000 V0140 A

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& WP4140
Figures
Fig. 1 Typical lifting device

Arrangement........................................................................
........... 219
218 HTGD 693 000 V0140 A

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MA -
HTGD090319V9000 -
Rotor
Lifting Device
1 PURPOSE
The rotor lifting device 800 is required for lifting out and in the turbine
rotors.
See the data sheet for arranging the device for lifting out and in Data sheet
the rotors, selecting the rope slings and the hoisting equip- HTGD 667
271
ment. Use only the ropes supplied with the turbine. Check the 1BSE 501
724
ropes for damage before use. Use the ropes only for this work.
The red mark on the ropes (splice area) must be located in a
straight area, do not bend this part of the rope.
Type 1
Type 2
BWAD0302_
A2955
Fig. 1 Typical lifting device Arrangement
Caution
The ropes must only be put on surfaces provided for lifting. Do not lift on
the journal
areas or sealing strips of the shaft seals! Protect the surface with some
protection
material like gasket or rubber material.
en HTGD 693 000 V0140 A

219
2 LIFTING OUT THE ROTOR

Precondition
Note
The turbine casing is aligned horizontally and the turbine rotor is in the
operating
position.
2.1 Check before lifting out the rotor

Check the axial displacement possibility of the turbine rotor in Test
certificate
the inner casing in accordance with the test certificate. HTGD
667 257
2.2 Lifting out the rotor

Protect the mating faces of the couplings, install some gaskets between the
two
coupling halves.
To secure the rotor from axial displacement install some axial guides, like
for exam-
ple allan wrenches.
Lift the turbine rotor a small distance to check that the rotor is
horizontal.
Note
Keep the rotor horizontal when lifting to prevent damage to blading and
sealing
elements. Monitor the horizontal position of the rotor during lifting with a
precision
water level.
Adjust the turnbuckle to keep the rotor horizontal.
Lift out the rotor carefully and exactly vertically.
Caution
The rotor must not jam during lifting; it must always be possible to move it
slightly.
Monitor the rotor on both sides when lifting it out of the turbine casing.
The sealing
elements and the blading must not rub.
Put the rotor on the prepared assembly supports. The rotor support surfaces
must
be protected. If the rotor is supported on the journal area, do not use
Teflon for pro-
tection!
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MA -
HTGD090319V9000 -
Rotor
Lifting Device
WARNING
Suspended Load
area.
3 LIFTING IN THE ROTOR
3.1 Lifting in the rotor

Lift the turbine rotor a small distance to check that the rotor is
horizontal.
Note
Keep the rotor horizontal when lifting to prevent damage to blading and
sealing
elements. Monitor the horizontal position of the rotor during lifting with a
precision
water level.
Adjust the turnbuckle to keep the rotor horizontal.
Align the rotor axially with the turbine axis using the hoisting equipment.
Lower the rotor carefully and exactly vertically into the inner casing.
Caution
The rotor must not jam during lowering; it must always be possible to move
the ro-
tor a small distance. Monitor the rotor on both sides when lowering it into
the tur-
bine casing . The sealing elements and the blading must not rub.
en HTGD 693 000 V0140 A

221
WARNING
Suspended Load
area.
Dismantle the rotor lifting device and store it at the appropriate place.
3.2 Check measurements after lifting in the rotor

Check the axial position of the turbine rotor in the inner casing Test
certificate
in accordance with the test certificate. HTGD 667
257
Check the radial and axial clearances of the stationary and ro- Test
certificate
tating blades in accordance with the test certificate. HTGD 457
160
Select the relevant test certificate.
Note
The rotor is again in the operating position relative to the turbine casing.
HTGD090319V9000
222 HTGD 693 000 V0140 A

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MA - HTGD693015V0001 -
Holding Device for hydraulic
tensioning cylinder
MA - HTGD693015V0001 -
tensioning cylinder
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Revision History
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224 HTGD 693 000 V0140 A en

MA - HTGD693015V0001 -
tensioning cylinder
Contents
1
PURPOSE............................................................................
..............................................................227
en HTGD 693 000 V0140 A

225
& WP4140
Figures
Fig. 1 Holder, place of installation at

bottom ............................................................................
. 227
Fig. 2 Holder, lateral place of
installation.......................................................................
............ 228
226 HTGD 693 000 V0140 A

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MA -
HTGD693015V0001 -
Holding Device for
hydraulic
tensioning cylinder
1 PURPOSE
The holder is required for positioning the hydraulic tensioning cylinders at
locations
where the cylinders cannot be directly lifted into place.
The spring-supported suspension head A compensates for movements of the ten-
sioning cylinder that can occur during stretching of the elongation bolts.
Fig. 1 shows how the tensioning cylinder 850 is moved from below to the
place of
installation using the holder 852 .

850 Hydraulic tensioning cylinder B Adapter
852 Holder C Elongation bolt
A Suspension head
Fig. 1 Holder, place of installation at bottom
Fig. 2 shows how the cylinder is moved from the side to the place of
installation.
en HTGD 693 000 V0140 A

227

850 Hydraulic tensioning cylinder B Adapter
852 Holder C Elongation bolt
A Suspension head
Fig. 2 Holder, lateral place of installation
Screw the tensioning cylinders to the holder using the adapters B, which
match the
different cylinders.
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MA -
HTGD693015V0001 -
Holding Device for
hydraulic
tensioning
cylinder
WARNING
Suspended Load
area.
Clean the holder after use and store it at the appropriate place.
en HTGD 693 000 V0140 A

229
Blank Page
HTGD693015V0001
230 HTGD 693 000 V0140 A en

MA - HTGD690059V9000 -
Disassembly and Re-assembly of the Expansion Sleeve Coupling
MA - HTGD690059V9000 -
Disassembly and Re-assembly of
the Expansion Sleeve Coupling
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Revision History
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232 HTGD 693 000 V0140 A en

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HTGD690059V9000 -
Disassembly and Re-assembly of the
Expansion Sleeve Coupling
Contents
1 DISASSEMBLY OF THE
COUPLING...........................................................................
.....................238
1.1
Preparations.......................................................................
.................................... 238
1.2 Installing the tensioning
devices ...........................................................................
. 239
1.3 Loosening the coupling
bolts .............................................................................
.... 239
1.3.1 Loosening the countersunk
nuts ............................................................... 239
1.3.2 Loosening the expansion
sleeves ............................................................. 240
1.4 Tensioning provisionally the coupling
bolts............................................................ 242
1.5
Dismantling .......................................................................
..................................... 242
1.5.1 Installing the tensioning
devices................................................................ 242
nuts ............................................................... 242
sleeves ............................................................. 242
1.5.4 Loosening the provisionally tensioned coupling
bolts ............................... 243
1.5.5 Final
work ..............................................................................
.................... 243
1.6 Inspecting the
coupling ..........................................................................
................ 244
1.6.1 Coupling
components.........................................................................
....... 244
1.6.2 Coupling
flanges............................................................................
............ 244
1.6.3 Applying the corrosion
inhibitor ................................................................. 245
2 RE-ASSEMBLY OF THE
COUPLING ..........................................................................
.....................248
2.1
Preparations.......................................................................
.................................... 248
2.2 Pulling together the coupling
flanges ..................................................................... 249
2.3 Aligning the
coupling...........................................................................
................... 250
2.3.1 Checking the
parallelism .......................................................................
.... 250
2.3.2 Measuring the angular
misalignment ........................................................ 251
2.3.3 Correcting the angular
misalignment......................................................... 251
2.4 Centring the
coupling ..........................................................................
................... 252
2.4.1
Preparations ......................................................................
........................ 252
2.4.2 Centring the coupling
bores ...................................................................... 252
2.4.3 Pulling together the
coupling ..................................................................... 253
2.4.4 Tensioning radially the centring
sleeves ................................................... 254
2.4.5 Tensioning provisionally the coupling
bolts ............................................... 255
2.5 Tensioning definitely the coupling
bolts ................................................................. 255
2.5.1 Inserting the coupling
bolts........................................................................ 256
2.5.2 Mounting the tensioning
device................................................................. 256
2.5.3 Pre-tensioning the coupling
bolts .............................................................. 257
en HTGD 693 000 V0140 A

233
WP4110 & WP4140
2.5.4 Measuring the fitting

clearance ................................................................. 258
2.5.5 Screwing on and marking the countersunk
nuts ....................................... 258
2.5.6 Tensioning the coupling
bolts.................................................................... 258
2.5.7 Removing the provisionally inserted coupling
bolts .................................. 259
2.5.8 Removing the centring
sleeves ................................................................. 260
2.5.9 Pre-tensioning the remaining coupling
bolts ............................................. 260
2.5.10 Tensioning definitely the coupling
bolts .................................................... 261
2.5.11 Checking the coupling
assembly............................................................... 261
2.5.12 Securing the countersunk
nuts.................................................................. 261
2.6 Checking the concentric
run ...............................................................................
... 262
2.7 Final
work ..............................................................................
................................ 262
Figures
Fig. 1-1 Bending back the locking

rings..............................................................................
....... 238
Fig. 1-2 Installing the tensioning
devices............................................................................
....... 239
Fig. 1-3 Installing the extension
tube...............................................................................
.......... 240
Fig. 1-4 Loosening the expansion
sleeves ...........................................................................
..... 241
Fig. 1-5 Tensioning provisionally the coupling
bolts .................................................................. 242
Fig. 1-6 Loosening the provisionally tensioned coupling
bolts .................................................. 243
Fig. 1-7 Forcing the coupling flanges out of the
recess............................................................. 244
Fig. 2-1 Pulling together the coupling
flanges ...........................................................................
249
Fig. 2-2 Inserting the jack
screws ............................................................................
.................. 250
Fig. 2-3 Centring the coupling
bores .............................................................................
............ 252
Fig. 2-4 Pulling together the
coupling ..........................................................................
.............. 253
Fig. 2-5 Tensioning radially the centring
sleeves ...................................................................... 254
bolts .................................................................. 255
Fig. 2-7 Inserting the coupling
bolts..............................................................................
............. 256
Fig. 2-8 Mounting the tensioning
device.............................................................................
....... 257
Fig. 2-9 Pre-tensioning the coupling
bolts .............................................................................
.... 258
Fig. 2-10 Removing the provisionally inserted coupling
bolts.................................................... 259
Fig. 2-11 Removing the centring
sleeves ...........................................................................
....... 260
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HTGD690059V9000 -
Expansion Sleeve Coupling
Fig. 2-12 Tensioning definitely the coupling

bolts...................................................................... 261
Fig. 2-13 Bending the locking
rings .............................................................................
.............. 262
Test certificates
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MA - HTGD690059V9000 -
CHAPTER 1
DISMANTLING OF THE EXPANSION SLEEVE COUPLING
en HTGD 693 000 V0140 A 237

1 DISASSEMBLY OF THE COUPLING

12
Refer to parts lists:
MAK.., MBK.., MKK..
Remark
Remove first four coupling bolts, staggered by approx. 90�, and tension
them provi-
sionally without expansion sleeves. This keeps parallel the coupling
flanges during
dismantling and facilitates the removal of the remaining coupling bolts.
1.1 Preparations
Bend back the locking rings 5 on both sides A and B of the coupling
according to
Fig. 1-1. Side B shows the secured operating position, side A the bent-
back position
of the locking rings.

3 Coupling bolt 5 Locking ring
4 Countersunk nut 6 Expansion sleeve
Fig. 1-1 Bending back the locking rings
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MA - HTGD690059V9000
-
Disassembly and Re-assembly of the Expansion Sleeve
Coupling
1.2 Installing the tensioning devices

Install the carrier ring 9 with mandrel 18 , support ring 11 and tensioning
device
23 on side A according to Fig. 1-2. In order to facilitate subsequent
removal of the
hydraulic cylinder 12 , maintain a clearance of 1 to 2 mm between the
hydraulic cyl-
inder and the support ring 11 .

3 Coupling bolt 9 Carrier ring
4 Countersunk nut 11 Support ring
5 Locking ring 12 Hydraulic cylinder
6 Expansion sleeve 18 Mandrel
7 Tension bolt 23 Tensioning device
Fig. 1-2 Installing the tensioning devices
1.3 Loosening the coupling bolts

1.3.1 Loosening the countersunk nuts
Build up a pressure of p3 + 5 MPa (max. p3 + 10 MPa) accord- Test
certificate
ing to the test certificate at connection C of the hydraulic cylin- HTGD
667 270
der 12 so that the countersunk nuts 4 can be loosened.
Loosen the countersunk nuts by 2 to 3 turns in order to achieve the gap "b"
of at
least 2 mm according to Fig. 1-2.
en HTGD 693 000 V0140 A

239
WARNING
Ejected component
Incorrect disassembly procedure can cause the coupling bolts to be ejected
from the bores during the subsequent work and cause injury.
Do not remove the countersunk nuts completely until the coupling bolts
are
withdrawn from the taper in the sleeve.
Decrease the oil pressure and remove the devices.
1.3.2 Loosening the expansion sleeves

Remove the screw plug 24, if provided, from the cone connections D of the
coupling
bolts 3.
Install the extension tube 21 according to Fig. 1-3.
Build up an oil pressure of p1 to p2 according to the test certifi- Test
certificate
cate at connection D so that the coupling bolts can be removed HTGD 667 270
axially from the expansion sleeves. The oil pressure at connec-
tion D shall not exceed p2 + 20 MPa.

3 Coupling bolt 6 Expansion sleeve
4 Countersunk nut 21 Extension tube
5 Locking ring 24 Screw plug
Fig. 1-3 Installing the extension tube
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Coupling
If the press fit of the coupling bolts 3 and expansion sleeves 6 cannot be
loosened
this way, lower the oil pressure at connection D. The extension tube 21
remains
installed.
Install an additional hydraulic device on side B of the coupling according to
Fig. 1-4.
Build up again an oil pressure of p1 to p2 according to the test Test
certificate
certificate at connection D (max. p2 + 20 MPa) and pressurise HTGD 667
270
simultaneously the hydraulic cylinder 12 via connection C.
Loosen the coupling bolts.
Note
During the entire loosening process the countersunk nuts of the coupling side
A
must remain on the coupling bolts, but loosened by 2 to 3 turns, gap "b", at
least 2
mm.

3 Coupling bolt 11 Support ring
4 Countersunk nut 12 Hydraulic cylinder
5 Locking ring 21 Extension tube
6 Expansion sleeve 23 Tensioning device
7 Tension bolt
Fig. 1-4 Loosening the expansion sleeves
Remove all parts and tools after unscrewing the four coupling bolts 3.
en HTGD 693 000 V0140 A

241
1.4 Tensioning provisionally the coupling bolts

Re-install the four coupling bolts 3 and countersunk nuts 4 Test
certificate
without expansion sleeves and locking rings and tension them HTGD 667 270
provisionally with an oil pressure of p2 according to the test cer-
tificate at connection C using the hydraulic tensioning device
according to Fig. 1-5.

7 Tension bolt 18 Mandrel
9 Carrier ring 23 Tensioning device
10 Face spanner
Fig. 1-5 Tensioning provisionally the coupling bolts
After attaining the oil pressure, tighten the countersunk nuts 4 with the
aid of the car-
rier ring 9 and the mandrel 18 .
1.5 Dismantling
1.5.1 Installing the tensioning devices
� Install the devices as described in paragraph 1.2.

� Loosen the countersunk nuts as described in paragraph 1.3.1.

� Loosen the expansion sleeves as described in paragraph 1.3.2.
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-
Coupling
1.5.4 Loosening the provisionally tensioned coupling bolts

Loosen the provisionally tensioned coupling bolts with the devices
installed accord-
ing to Fig. 1-6.

10 Face spanner
Fig. 1-6 Loosening the provisionally tensioned coupling bolts
1.5.5 Final work

Remove the tools and dismantle the coupling components. Store the tools in
the tool
cabinets.
Press the coupling out of the recess according to Fig. 1-7 using the jack
screws.
For this purpose screw two diametrically opposite jack screws 22
into the balanc-
ing holes of the coupling flanges.
en HTGD 693 000 V0140 A

243

22 Jack screw
Fig. 1-7 Forcing the coupling flanges out of the recess
Caution
Make sure that both rotors rest on their journal areas, auxiliary bearings
or rotor
lifting devices.
Remove again the jack screws, clean and store them in the tool cabinet.
1.6 Inspecting the coupling

1.6.1 Coupling components
Check all coupling bolts, countersunk nuts and expansion sleeves for seized
parts,
deformation or other damage.
Replace defective or damaged parts by new ones before re-assembly.
1.6.2 Coupling flanges

� Check the coupling flanges and the areas contacting the coupling
components in
the same manner. Inspect these parts additionally for a correct
protective coating.
If this protective coating is defective or no longer provided, proceed as
follows:
� Clean the relevant surfaces and thoroughly degrease them with a solvent
such as
spirit.
� Clean mechanically corroded surfaces using a wire brush or emery cloth.
Note
Do not use emery disks.
Remove completely corrosion pits at the undercuts. Local finish-grinding

and polish-
ing for smoothening the transitions is permitted.
244 HTGD 693 000 V0140 A

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MA - HTGD690059V9000 -
Coupling
The surfaces must have a roughness of 1.6 m (N 7) after polishing.
1.6.3 Applying the corrosion inhibitor

Spray or spread a corrosion inhibitor with a thickness of at least 30 m on
the
cleaned surfaces of the coupling flanges.
Use Universalgrund GK 128, obtainable via the ALSTOM-Service Department, or
another product, which complies with the ALSTOM specification, as corrosion
inhibi-
tor.
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246 HTGD 693 000 V0140 A en

MA - HTGD690059V9000 -
CHAPTER 2
RE-ASSEMBLY OF THE EXPANSION SLEEVE COUPLING
en HTGD 693 000 V0140 A 247

2 RE-ASSEMBLY OF THE COUPLING

12
Refer to parts list:
MAK.., MBK.., MKK..
Preliminary remark
To prevent bending stresses, screw together the two coupling flanges, so
that they
are exactly parallel, observing the prescribed tolerances.
2.1 Preparations
The journal areas must be adjusted in accordance with the calculated
deflection line
before installing the turbine rotors.
Measure the elevation of the journal areas and record the val- Test
certificate
ues in the alignment diagram. 1BSE
501 730
The positions of the journal areas must be checked even if they were not
changed
during maintenance.
The rotors must be straight and not deformed due to heat.
Note
The rotors may only rest on the journal areas and not on the auxiliary
bearings or
similar units when checking the alignment condition.
All heavy machine parts must be at their correct location so that the
deflection line of
the foundation table corresponds to the line expected in operation.
The rotor zero markings (bores, 4 mm) must align in the longitudinal
axis of the
turbine line.
248 HTGD 693 000 V0140 A

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Coupling
2.2 Pulling together the coupling flanges

Pull together the two coupling flanges with the two coupling bolts 3 to a gap
"a" = 1
mm according to Fig. 2-1 using the hydraulic tensioning device 23 and minimum
oil
pressure at connection C.

10 Face spanner
Fig. 2-1 Pulling together the coupling flanges
The jacking oil system must be in operation when pulling together the
coupling
flanges.
Insert two jack screws 22 diametrically opposite and staggered by 90�
relative to
the coupling bolts into the bores for the balancing plugs according to Fig.
2-2.
en HTGD 693 000 V0140 A

249

22 Jack screw
Fig. 2-2 Inserting the jack screws
Tighten slightly the jack screws to prevent the rotor from moving axially
when rotat-
ing it for taking the measuring series.
Adjust dimension "a" according to the test certificate. Test
certificate
HTGD 667
270
2.3 Aligning the coupling

2.3.1 Checking the parallelism
Checking the parallelism means measuring the angular misalignment and axial
run-
out of the coupling flanges relative to one another.
Both faults manifest themselves in the same way (different gap width "a" on
the cir-
cumference of the coupling) and can only be measured as the sum of both.
The system described in the test certificates allows, however, correction
of the angu-
lar misalignment.
The angular misalignment (incorrect alignment) is caused by faulty erection
and can
be completely eliminated by correcting the horizontal and vertical
positions of the
journal areas.
The axial run-out (the coupling faces are not exactly perpendicular to the
rotor axes
due to admissible tolerances) is a manufacturing defect and cannot be
corrected.
The tolerance for the axial run-out of each coupling face may not exceed
0.015 mm.
250 HTGD 693 000 V0140 A

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-
Coupling
2.3.2 Measuring the angular misalignment

The angular misalignment is determined by four measuring series. A
measuring se-
ries consists of measuring the gap width "a" at four exactly defined points
on the
coupling circumference.
Take the measuring series according to the test certificate for Test
certificate
"left", "right", "top" and "bottom". HTGD
667 270
Note
The jacking oil system must be switched off when taking the measurements
be-
cause its pulsations could affect the measurement results.
Proceed as follows for taking a measuring series:

� Switch off the jacking oil system.
� Loosen the jack screws by about 1/4 turn.
� Loosen the coupling bolts by about 1/4 turn.
� Measure the distances "a" at the points "left", "right", "top" and
"bottom" and enter
the values in the test certificate. In most cases it is not possible to
measure at
point "bottom"; this, however, does not affect the result.
� Tighten slightly the coupling bolts and jack screws. Maintain the
distance "a" max.
1 mm.
� Start the jacking oil system and rotate the rotor through 90� each time.
Evaluate
the data obtained by the four measuring series. Carry out the necessary
correc-
tions in two steps.
2.3.3 Correcting the angular misalignment

First step
� Correct angle = horizontal component of the angular misalignment by
lateral
shifting of the journal area(s) until the mean values of the measuring
points "left"
and "right" are identical or at least within the tolerances given in the
test certifi-
cate.
� Try to reach the ideal case "left" = "right".
Second step
� Correct angle = vertical component of the angular misalignment by
lifting or
lowering the journal area(s) until the mean values of the measuring
points "left",
"right", "top" and "bottom" are identical or at least within the
tolerances given in
the test certificate.
� Try to reach the ideal case "left" = "right" = "top" = "bottom".
� Remove the jack screws and coupling parts.
en HTGD 693 000 V0140 A

251
2.4 Centring the coupling

2.4.1 Preparations
Check whether the coupling flanges align radially and whether the rotor
zero mark-
ings, bores with a dia. of 4 mm, are in alignment in longitudinal direction
along the ro-
tor axis.
Clean the coupling bores and switch on the jacking oil system.
Note
Lubricate all coupling parts to be installed provisionally and all coupling
bores with
MoS2 powder 1 or Neolube No. 2 to permit easier dismantling.
2.4.2 Centring the coupling bores

Align the coupling bores with the aid of two centring sleeves 19 ,
installed diametri-
cally opposite, and coupling bolts 3 according to Fig. 2-3.

3 Coupling bolt 19 Centring sleeve
Fig. 2-3 Centring the coupling bores
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-
Coupling
2.4.3 Pulling together the coupling

Insert provisionally four coupling bolts 3 with countersunk nuts 4,
staggered by about
90�, and tighten them completely according to Fig. 2-4 using the tensioning
device
23 and minimum oil pressure at connection C of the hydraulic cylinder.

10 Face spanner
en HTGD 693 000 V0140 A

253
2.4.4 Tensioning radially the centring sleeves

Tension radially the already installed centring sleeves 19 and Test
certificate
coupling bolts 3 according to Fig. 2-5 using the tensioning de- HTGD 667
270
vice 23 and an oil pressure of p1 + 10 MPa according to the
test certificate at connection C of the hydraulic cylinder.

7 Tension bolt 12 Hydraulic cylinder
8 Spacer ring 19 Centring sleeve
10 Face spanner 23 Tensioning device
Fig. 2-5 Tensioning radially the centring sleeves
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-
Coupling
2.4.5 Tensioning provisionally the coupling bolts

Tension provisionally the four inserted coupling bolts 3, without Test
certificate
expansion sleeves, according to Fig. 2-6 using the tensioning HTGD
667 270
device 23 and an oil pressure of p2 according to the test cer-
tificate at connection C of the hydraulic cylinder.

10 Face spanner
2.5 Tensioning definitely the coupling bolts

Note
Clean thoroughly all coupling parts and coupling bores before the definite
assem-
bly.The surfaces of the expansion sleeves are browned or phosphated; this
coating
may not be damaged or removed.
Lubricate the coupling parts to be installed and the coupling bores
completely and
adequately with MoS2 powder 1 or Neolube No. 2.
en HTGD 693 000 V0140 A

255
2.5.1 Inserting the coupling bolts

Insert the coupling bolts 3 with mounted expansion sleeves 6 in center
position in the
coupling bore according to Fig. 2-7. The large opening of the internally
conical ex-
pansion sleeve is on side B, which has less space. Use the tension bolt 7
for posi-
tioning.

3 Coupling bolt 7 Tension bolt
6 Expansion sleeve
Fig. 2-7 Inserting the coupling bolts
2.5.2 Mounting the tensioning device

Mount the spacer ring 8 and the support ring 11 on the coupling bolt
and the ten-
sion bolt according to Fig. 2-8.
Note
Position the bevelled area of the support ring parallel to the shaft
contour to pre-
vent grooves in the coupling flange. The support ring must always rest
against the
coupling flange.
Bolt the tensioning device 23 to the tension bolt according to Fig. 2-8
until the
spacer ring 8 is pressed against the expansion sleeve 6.
Before tensioning the expansion sleeves check with a 0.02 mm feeler gauge
at four
points of the coupling flange circumference, staggered by 90� each time,
whether the
coupling flanges have been completely pulled together.
256 HTGD 693 000 V0140 A

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HTGD690059V9000 -
Coupling

3 Coupling bolt 10 Face spanner
6 Expansion sleeve 11 Support ring
8 Spacer ring 23 Tensioning device
Fig. 2-8 Mounting the tensioning device
It must still be possible to rotate all installed parts, including the

tools, as a single unit
in the coupling bore.
2.5.3 Pre-tensioning the coupling bolts

Build up the pressure p1 according to the test certificate at connection C
of the hy-
draulic cylinder.
Note
Check whether the support ring still rests against the coupling flange.
The material of the expansion sleeve is such that the pulling force of the
tensioning
device expands the expansion sleeve which eliminates the clearance between
the
expansion sleeve and the coupling bore and provides radial pre-tension.
If the unit consisting of coupling bolt and expansion sleeve can still be
rotated with
the tensioning device, increase the pressure p1 in steps of 50 bar until a
clearance-
free fit is ensured.
Record the actually built-up pressure p1 in the test certificate.
Test certificate
HTGD 667 270
Decrease the oil pressure p1 and remove the tools .
en HTGD 693 000 V0140 A

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2.5.4 Measuring the fitting clearance

Measure the fitting clearance "S", min.: 2 mm, to ensure that the
countersunk nuts to
be installed rest on the support surfaces of the coupling flange and not on
the ex-
pansion sleeve.
Measure the dimension "S" with a depth gauge or similar Test
certificate
measuring instrument and record the value in the test certifi- HTGD
667 270
cate.
2.5.5 Screwing on and marking the countersunk nuts

Screw on the countersunk nuts 4 with locking rings 5 according to Fig. 2-9
and
tighten them manually. Apply markings on the facesides of the countersunk
nuts and
on the coupling flange to check the angle of rotation after tightening.
2.5.6 Tensioning the coupling bolts

Install the carrier ring 9 , support ring 11 and tensioning device 23
according to
Fig. 2-9.

9 Carrier ring
Fig. 2-9 Pre-tensioning the coupling bolts
Build up the oil pressure according to the test certificate via an

intermediate pressure
p2 at connection C and tighten the nuts on coupling side A using the
mandrel 18
and the carrier ring 9 . The sequence of tightening the coupling bolts is
optional.
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Coupling
Record the oil pressure p2 in the test certificate. Test

certificate
HTGD
667 270
Decrease the oil pressure and remove the tools .
2.5.7 Removing the provisionally inserted coupling bolts

Remove again the four coupling bolts, which were inserted without expansion
sleeves, according to Fig. 2-10.

10 Face spanner
Fig. 2-10 Removing the provisionally inserted coupling bolts
en HTGD 693 000 V0140 A

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2.5.8 Removing the centring sleeves

Remove again the two coupling bolts, inserted with slotted centring
sleeves, accord-
ing to Fig. 2-11.

3 Coupling bolt 12 Hydraulic cylinder
7 Tension bolt 19 Centring sleeve
8 Spacer ring 20 Intermediate ring
11 Support ring
Fig. 2-11 Removing the centring sleeves
2.5.9 Pre-tensioning the remaining coupling bolts

Pre-tension the remaining six coupling bolts according to 2.5.1 through
2.5.6 in the
same way and record the oil pressure p2.
certificate
HTGD
667 270
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Coupling
2.5.10 Tensioning definitely the coupling bolts

Tension all coupling bolts with the definite oil pressure p3 according to
the test certifi-
cate in optional sequence according to Fig. 2-12.
Maintain a clearance of 1-2 mm between the hydraulic cylinder and the
support ring
11 when screwing on the cylinder to facilitate subsequent dismantling of
the hy-
draulic cylinder 12 .

Fig. 2-12 Tensioning definitely the coupling bolts
2.5.11 Checking the coupling assembly

Compare the angles of rotation of the countersunk nuts 4 with the aid of
the mark-
ings to check the coupling assembly. Check the oil pressure p3 in case of
deviations
and re-tension, if necessary.
Record the definite oil pressure p3 in the test certificate. Test
certificate
HTGD
667 270
2.5.12 Securing the countersunk nuts

Secure the countersunk nuts according to Fig. 2-13 on sides A and B of the
coupling
flanges by bending up and in the locking rings 5.
Side A shows the unsecured, side B the secured condition.
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Note
The coupling bolts shall not project beyond the countersunk nuts.

4 Countersunk nut 24 Screw plug
5 Locking ring
Fig. 2-13 Bending the locking rings
2.6 Checking the concentric run

The assembly of the coupling is extremely important for the smooth running of
the
turboset.
It is therefore necessary to check the concentric run of all assembled
couplings.
Check the concentric run of the coupling, assembled thor- Test
certificate
oughly and in accordance with instructions, according to the HTGD 667
270
test certificate.
Note
Inadmissible radial run-out defects of a coupling can be caused by damages.
2.7 Final work

Coat the complete coupling with an anticorrosive like Tectyl 506 or Tectyl
175-GW
after checking the concentric run.
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Coupling
Clean thoroughly all tools used, check their completeness and store them in
the
tool cabinets.
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HTGD690059V9000
264 HTGD 693 000 V0140 A en

MA - HTGD691538V0004A -
ITH Torque Wrench Equipment Type DR
MA - HTGD691538V0004A -
ITH Torque Wrench Equipment
Type DR
en HTGD 693 000 V0140 A 265

Revision History
total :
A Edit content;11-03-05 -
- - (22)
266 HTGD 693 000 V0140 A en

MA - HTGD691538V0004A -
Contents
1 NOTE ON
SAFETY.............................................................................
...............................................269
2 OPERATING INSTRUCTION FOR TORQUE WRENCH
UNIT ........................................................270
2.1 Electrical
Instructions ......................................................................
....................... 270
2.2 Control
connection ........................................................................
......................... 270
2.3 Hydraulic connection on
unit...............................................................................
... 270
2.4 Torque
setting ...........................................................................
............................. 271
2.5
Adapters...........................................................................
...................................... 272
2.6 Right-hand
turn ..............................................................................
........................ 272
2.7 Left-hand
turn...............................................................................
.......................... 273
2.8
Adapter ...........................................................................
....................................... 273
2.9 Support arm on torque
wrench ............................................................................
.. 273
2.10 Hydraulic connection to torque
wrench.................................................................. 274
2.11 Support position for
torque.............................................................................
........ 274
2.12 Operation of the torque
wrench ............................................................................
. 275
2.13 Achiving the
torque ............................................................................
.................... 276
2.14 Switching
off................................................................................
........................... 277
3 BRIEF OPERATING
INSTRUCTIONS ......................................................................
........................278
3.1 BEFORE STARTING

OPERATION.......................................................................
278
3.2 OPERATION OF THE ITH TORQUE
WRENCH ................................................... 278
3.2.1 Operation with Hand-Lever High Pressure Pump Assembly (H-HD-
A).................................................................................
.............................. 278
3.2.2 Operation with Electric High Pressure Pump Assembly (E-HD-
A)............ 279
3.2.3 Operation with Pneumatic High Pressure Pump Assembly (P-HO-
A).................................................................................
.............................. 279
4 OPERATING INSTRUCTION FOR TORQUE
INDICATOR ..............................................................280
5 TORQUE CHART DRAWING-NO.:
09.80053 ..........................................................................
.........281
6 Torque and Pressure schedule for torque wrenches Types DG, DR,and
DOS ................................283
7 SPARE PARTS AND
ACCESSORIES .......................................................................
.......................285
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267
WP4110 & WP4140
Figures
Fig. 2-1 Electrical

Instructions ......................................................................
............................. 270
Fig. 2-2 Control
connection ........................................................................
............................... 270
Fig. 2-3 Hydraulic connection on
unit ..............................................................................
.......... 271
Fig. 2-4 Torque
setting ...........................................................................
................................... 271
Fig. 2-5
Adapters ..........................................................................
............................................. 272
Fig. 2-6 Right-hand
turn...............................................................................
.............................. 272
Fig. 2-7 Left-hand
turn ..............................................................................
................................. 273
Fig. 2-8
Adapter............................................................................
............................................. 273
Fig. 2-9 Support arm on torque
wrench.............................................................................
........ 274
Fig. 2-10 Hydraulic connection to torque
wrench ...................................................................... 274
Fig. 2-11a Support position for
torque ............................................................................
........... 275
Fig. 2-11b Support position for
torque ............................................................................
........... 275
Fig. 2-12 Operation of the torque
wrench.............................................................................
..... 276
Fig. 2-13 Achiving the
torque.............................................................................
........................ 276
Fig. 2-14 Switching
off ...............................................................................
................................ 277
Fig. 2-15 Torque
Indicator .........................................................................
................................ 280
Fig. 2-16 Torque and Pressure schedule for torque wrenches Types DG, DR,and
DOS ......... 284
Fig. 2-17 SPARE PARTS AND
ACCESSORIES.......................................................................
285
Datasheets of torque wrench unit
Datasheets of high pressure pump units
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ITH Torque Wrench Equipment Type
DR
1 NOTE ON SAFETY
1. The electrical units should be used only in the areas for which they are
Iicensed.
If necessary, explosion-protected types should be used in other areas.
2. For the electrical connection, the VDE Guidelines must be complied with.
Inspec-
tion and maintenance work on electrical components should be carried out
only
by authorized and qualified persons.
3. The wrench and the electric power unit should not be connected until after
the
torque has been set.
4. The support force must be absorbed by firmly anchored and stable machinery
components. If necessary, special support arms must be used.
5. Before beginning work, ensure that the support arm is firmly positioned.
6. Before switching on the pump, ensure that there is no contact between any
part of
the body and the support arm or support surface.
7. When working with the torque wrench, stay at a safe distance if possible.
8. When joining the couplings, ensure that the lock clicks firmly into
position.
9. With the torque wrench of type DR, the support arm must be secured by the
lock-
ing pin.
10.The torque wrenches should be operated only with hydraulic units
manufactured
by ITH. Before using hydraulic units of other types, please consult ITH.
11.When replacing the hydraulic fluid, the manufacturer's instructions must be
ob-
served.
12.When working with hydraulic torque wrenches, always observe the general
acci-
dent-prevention regulations. It is prohibited to stand in front of the
torque wrench
when it is under high pressure.
The safety precautions required are dependant on the application in question
and are the responsibility of the user.
en HTGD 693 000 V0140 A

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2 OPERATING INSTRUCTION FOR TORQUE WRENCH UNIT

2.1 Electrical Instructions
The main power connection is made by plugging in the EEC coupling. When
insert-
ing the plug, ensure that there are three live phases and an earth (for 230 V
single-
phase AC, one live phase only). A neutral conductor is not required.
Fig. 2-1 Electrical Instructions
2.2 Control connection

Screw the multiple-pole plug for the remote control into the socket in the
housing and
secure with fixing nut.
Fig. 2-2 Control connection
2.3 Hydraulic connection on unit

In delivery state the pump is fitted with plug (DIN 908). Before using the
pump screw
the vented oil - measuring device (enclosed) into position.
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Fig. 2-3 Hydraulic connection on unit
The connection between the high-pressure pump unit and the torque wrench is
made by coupling the high-pressure hose into position.
CAUTION
Important:
If the unit is being transported over a greater distance, replace
the oil -
measuring device with the original plug, otherwise oil may flow out.
2.4 Torque setting

The electric motor is switched on by pressing the white switch on the remote
control.
Keep the white switch pressed and turn the hand wheel on the pressure-
limiting
valve until the desired torque is reached on the pressure gauge. The pressure
gauge
has different torque scales for torques of up to 850 bars can be read
directly off the
pressure gauge. For torque wrenches of type DR the scales DG 2.0 - DG 16.5
also
apply up to 850 bars. In addition, the pressure scale and the torque tables
must also
be used (see 6). After setting the torque, the pump is switched off again by
pressing
the black switch.
Fig. 2-4 Torque setting
en HTGD 693 000 V0140 A

271
2.5 Adapters
Depending on the application, a number of different adapters can be used for
the
torque wrench. As shown in our catalogue, there is a choice of three
different stan-
dard adapters.
1. Special power-wrench insert for standard nuts, type KSE
2. Special power-wrench insert for Allen bolts type SE
3. Special power-wrench insert for hexagon bolts, type VE
4. Special types can be ordered at any time. In this case, the retaining
socket is the
same as that for the standard adapters.
Fig. 2-5 Adapters
2.6 Right-hand turn

The illustration shows the torque wrench in the position for right-hand
turning (tight-
ening). The correct adapter should be pushed into the opposite side.
Fig. 2-6 Right-hand turn
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DR
2.7 Left-hand turn

The illustration shows the torque wrench in the position for left-hand
turning (loosen-
ing). The correct adapter should be pushed into the opposite side.
Fig. 2-7 Left-hand turn
2.8 Adapter
When the correct power-wrench insert has been selected, this is inserted into
the
torque wrench. Inserts are prevented from dropping out by a ball. For larger
inserts,
a securing lock can also be fitted.
Fig. 2-8 Adapter
2.9 Support arm on torque wrench

Depending on the type of bolted joint, the torque wrench can also be used
with a
support arm. The support arm can also be adapted to the type of bolted joint.
Before
coupling the hose onto the torque wrench, the correct support arm must be
pushed
onto the unit. To do this, press the locking button of the support arm and
push it onto
the torque wrench. Allow the locking button to click into position at the
desired set-
ting.
en HTGD 693 000 V0140 A

273
Fig. 2-9 Support arm on torque wrench
CAUTION
Important:
The torque wrench must not be used before the locking button has
clicked
into position. The direction of the support arm is determined by
the existing
support possibilities.
2.10 Hydraulic connection to torque wrench

The connection between the high-pressure pump unit and the torque wrench is
made by coupling the high-pressure hose into position. For work in confined
spaces,
it is advisable to use a coupling elbow to avoid kinks in the hose.
Fig. 2-10 Hydraulic connection to torque wrench
2.11 Support position for torque

Fit the correct insert to the torque wrench. Fit the support arm to the
torque wrench.
Connect the hydraulic hose to the torque wrench. If necessary, use an elbow
cou-
pling. Position the torque wrench on the bolt. Determine the support point.
If possi-
ble, this should be in a straight line with the housing axis. If this is not
possible, turn
the support arm up to 90� to the housing axis.
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HTGD691538V0004A -
Type DR
Fig. 2-11a Support position for torque
Fig. 2-11b Support position for torque
CAUTION
Important:
The torque wrench must not be used before the locking button of the
sup-
port arm has clicked into position.
2.12 Operation of the torque wrench

First, set the torque as described. The electric solenoid valve is activated
by pressing
the white button on the hand switch of the remote control. This causes the
insert 25
and 36� depending on the type of torque wrench in use. The turning movement
is
executed only when the white button of the hand remote control remains
pressed.
When the torque wrench has turned the bolt through 25 - 36�, the white
button must
be released immediately to allow the cylinder of the torque wrench to return
to ist
starting position. This is extremely important to avoid excessive wear and
tear on the
pis-ton-return system. This procedure must be repeated until the torque
wrench no
longer turns the bolt when the white button is pressed.
en HTGD 693 000 V0140 A

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Fig. 2-12 Operation of the torque wrench
2.13 Achiving the torque

When a torque is selected, the torque wrench must be operated until the
sleeve of
the torque wrench with the insert no longer turns even when the white button
is
pressed. If the white button is pressed again, the hydraulic cylinder is
again pressur-
ized, and the current torque is indicated on the pressure gauge. Following
this, the
unit must be switched.
Fig. 2-13 Achiving the torque
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DR
2.14 Switching off

When the black button on the hand switch of the remote control is pressed,
the
torque wrench is switched off. The motor must be switched off every time the
torque
wrench is positioned on a new bolt.
Fig. 2-14 Switching off
en HTGD 693 000 V0140 A

277
3 BRIEF OPERATING INSTRUCTIONS

3.1 BEFORE STARTING OPERATION
1. Determine the desired torque (this is essential when bolts are being
tightened).
The high-pressure hose should not be connected.
2. Measure the wrench span of the bolt-joint in order that the correct
adapter can be
selected.
3. Fix a support point for the torque wrench (if possible, without using
the supporting
arm or bolt), thus avoiding tilting.
4. If using a hand-lever high-pressure pump assembly, select a safe and
secure lo-
cation.
5. If using an electric pump assembly, check the live current-bearing
phases and the
earth lead.
6. If using a pneumatic pump assembly, check the compressed air for
cleanness
and sufficient pressure (minimum 4,5 bars).
3.2 OPERATION OF THE ITH TORQUE WRENCH

1. Insert the adapter into the high torque wrench.
2. Connect hose to the pump assembly and to the wrench.
3. Place the torque wrench on the desired bolt. Select the correct side
(loosening or
tightening), and swivel into position against the previously selected
support point.
4. If the torque wrench should rise off the support point, it should be
returned to the
correct position. The ratches is clearly audible.
3.2.1 Operation with Hand-Lever High Pressure Pump Assembly (H-HD-A)

1. Close the pressure relief valve..
2. Generate pressure with lever on the pump assembly. When the torque
wrench
has revolved through approx. 30�, open the pressure relief valve on the
pump as-
sembly. This process should be repeated as often as necessary, until the
wrench
stops revolving and the desired torque is shown on the indicator.
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HTGD691538V0004A -
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3.2.2 Operation with Electric High Pressure Pump Assembly (E-HD-A)

1. The electric motor is switched on and the revolving motion of the torque
wrench is
triggered by depressing the white push button on the hand switch. When
the
torque wrench has revolved through approx. 30�, release the push button.
This
process should be repeated as often as necessary, until the wrench stops
revolv-
ing and the desired torque is shown on the indicator.
2. The electric assembly is switched off by pressing the black button on
the hand
switch.
3.2.3 Operation with Pneumatic High Pressure Pump Assembly (P-HO-A)

1. Open the compressed air shutoff valve. The revolving motion of the
wrench is
triggered by depressing the push button hand valve. When the torque
wrench has
revolved through approx. 30�, release the push button hand valve. This
process
should be repeated as often as necessary, until the wrench stops
revolving and
the desired torque appears on the indicator.
2. The pneumatic assembly is switched off by closing the compressed air
shutoff
valve.
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279
4 OPERATING INSTRUCTION FOR TORQUE INDICATOR
Fig. 2-15 Torque Indicator
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MA - HTGD691538V0004A -
ITH
Torque Wrench Equipment Type DR
5 TORQUE CHART DRAWING-NO.: 09.80053

Firmnessclass after DIN 267
3,6(4D) 5,6(5D) 6,9(6G) 8,8(8G)
10,9(10K) 12,9(12K)
PV MA PV MA PV MA PV MA
PV MA PV MA
kp kpm kp kpm kp kpm kp kpm
kp kpm kp kpm
M2 29.0 0.0125 38.5 0.0165 74.5 0.032 88 0.038
124 0.053 149 0.064 4
M 2,3 41.5 0.020 55.5 0.027 107 0.052 127 0.061

179 0.086 214 0.103 4.5
M 2,6 53.5 0.029 71.5 0.038 138 0.074 163 0.088

229 0.123 275 0.148 5
M3 74 0.045 98.5 0.060 190 0.115 225 0.137

317 0.192 380 0.230 5.5
M 3,5 99 0.069 132 0.092 255 0.177 302 0.21

425 0.295 510 0.355 6
M4 128 0.102 171 0.137 329 0.265 390 0.31

548 0.440 658 0.525 7
M5 210 0.20 279 0.27 539 0.520 638 0.615

898 0.865 1'080 1.04 8-9
M6 296 0.35 394 0.46 760 0.890 901 1.05

1'265 1.5 1'520 1.80 10
M7 432 0.57 576 0.76 1'110 1.45 1'320 1.75

1'855 2.5 2'220 2.9 11-12
M8 542 0.84 723 1.1 1'395 2.2 1'655 2.6

2'320 3.6 2'790 4.3 13-14
M10 864 1.7 1'150 2.2 2'220 4.3 2'630 5.1

3'700 7.2 4'440 8.7 15-17
M12 1'260 2.9 1'680 3.9 3'240 7.5 3'840 8.9

5'400 12.5 6'480 15.0 19-21
M14 1'730 4.6 2'310 6.2 4'450 11.9 5'270 14.1

7'410 19.8 8'900 24.0 22-23
M16 2'380 7.1 3'170 9.5 6'120 18.2 7'260 21.5

10'200 30.5 12'250 36.5 24-26
M18 2'890 9.7 3'860 13.0 7'440 25.0 8'820 29.5

12'400 42.0 14'900 50.0 27
M20 3'720 13.8 4'960 18.4 9'570 35.5 11'350 42.0

15'950 59.0 19'150 71.0 30
M22 4'650 18.6 6'200 25.0 11'950 48.0 14'200 57.0

19'950 80,0 23'900 96.0 32
M24 5'360 23.5 7'140 31.5 13'800 61.0 16'350 72.5

23'000 102 27'600 122 36
M27 7'060 35.0 9'410 47.0 18'150 90.5 21'500 107

30'200 151 36'300 181 41
M30 8'570 47.5 11'450 63.5 22'000 123 26'100 145

36'700 205 44'100 245 46
M33 10'700 64.5 14'250 86.5 27'500 166 32'600 197

45'800 277 55'000 333 50
M36 12'550 83,0 16'750 111 32'300 214 38'200 253

53'800 356 64'500 428 55
M39 15'100 108 20'100 144 38'800 277 46'000 329

64'600 462 77'600 555 60
M42 17'250 133 23'000 178 44'400 343 52'600 407

74'000 572 88'800 686 65
M45 20'200 167 27'000 222 52'000 429 61'600 509

86'700 715 104'000 858 70
M48 22'700 202 30'300 269 58'500 518 69'300 614

97'500 864 117'000 1'035 75
M52 27'300 259 36'400 346 70'200 667 83'200 790

117'000 1'110 140'500 1'335 80
M56 31'500 323 42'000 431 80'900 831 95'900 984

135'000 1'385 162'000 1'660 85
M60 36'800 401 49'100 535 94'600 1'030 112'000 1'220

157'500 1'720 189'000 2'060 90
M64 41'600 483 55'500 643 107'000 1'240 127'000 1'470

178'500 2'070 214'000 2'480 95
en HTGD 693 000 V0140 A

281
Remark:
The above mentioned prestressing forces P (in kp) and torques Ma (in kprn)
are rec-
ommended values for metric control thread after DIN 13 and head on-layed
meas-
ures after DIN 912, 931, 934, 6912, 7984 and 7990. They produce a screw-
stretch
limit of 70 %. A friction coefficient was based upon (new screw, without
after-
treatment, unlubricated).
If you should not attract your connection of screws up to the screw-stretch
limit of 70
% , the values mentioned in the table are to be reduced accordingly. In this
case, this
are the maximum values. Recommended are attempts with that screw-connection,
which should be attracted torque and pressure schedule for torque wrenches
Types
DG, DR,and DOS.
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6 TORQUE AND PRESSURE SCHEDULE FOR TORQUE

WRENCHES TYPES DG, DR,AND DOS
en HTGD 693 000 V0140 A 283

Fig. 2-16 Torque and Pressure schedule for torque wrenches Types DG, DR,and
DOS
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7 SPARE PARTS AND ACCESSORIES
Fig. 2-17 SPARE PARTS AND ACCESSORIES
en HTGD 693 000 V0140 A 285

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HTGD691538V0004
286 HTGD 693 000 V0140 A en

MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
en HTGD 693 000 V0140 A 287

Revision History
total :
A 2003-08-29, Change of Layout (Standard template) -
- - (58)
288 HTGD 693 000 V0140 A en

MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
Contents
1 SCHEMATIC DIAGRAM: HYDRAULIC TENSIONING

DEVICE .......................................................294
2 PREVENTION OF ACCIDENTS AND DAMAGE TO
EQUIPMENT ..................................................296
2.1 Bolt-Tensioning
Cylinder...........................................................................
............. 296
2.1.1 Operating
data...............................................................................
............ 296
2.1.2 Thread
projection ........................................................................
.............. 297
2.1.3 Angular
accuracy...........................................................................
............ 297
2.1.4 Bolt
preparation .......................................................................
.................. 298
2.1.5 Maximum number of
cycles....................................................................... 299
2.1.6 Piston
return ............................................................................
.................. 300
2.1.7 Using the bolt-tensioning
cylinder ............................................................. 301
2.1.8 Bending
stresses...........................................................................
............ 301
2.2 High pressure pump
units .............................................................................
......... 302
2.2.1 Electrical
installation.......................................................................
........... 302
2.2.2 Pumps with pressure adjusting
valve ........................................................ 303
2.3 Pumps with connected
cylinder ..........................................................................
... 303
2.4 Prolonging life of the
pumps .............................................................................
..... 304
2.5 Hose
line ..............................................................................
.................................. 305
2.5.1 Damage to high-pressure hose
line .......................................................... 305
2.5.2 Test Pressure Gauge for All
Units............................................................. 306
2.5.3 Operating
pressure...........................................................................
......... 306
2.5.4 Safety
distance...........................................................................
............... 307
2.5.5
Stroke ............................................................................
............................ 308
2.5.6 General safety
instructions.......................................................................
. 308
2.5.7
Storage............................................................................
.......................... 309
3 OPERATING
INSTRUCTION .......................................................................
.....................................309
3.1 Before Using the Bolt-Tensioning

Cylinder ............................................................ 309
3.1.1 Operating
instructions ......................................................................
......... 309
3.1.2 Positioning the
unit ..............................................................................
...... 310
3.1.3
Settling ..........................................................................
............................ 310
3.1.4 Piston
return ............................................................................
.................. 311
3.1.5 Determining tensioning force, operating
pressure..................................... 312
3.1.6 Maximum number of load
cycles............................................................... 314
3.2 Tightening of
Bolts .............................................................................
.................... 315
3.2.1 Thread
projection ........................................................................
.............. 315
3.2.2 Adjusting
ring...............................................................................
.............. 316
en HTGD 693 000 V0140 A

289
WP4110 & WP4140
3.2.3 Counter-
tightening.........................................................................
............ 317
3.2.4 Bolt
on ................................................................................
....................... 317
3.2.5
Checking ..........................................................................
......................... 318
3.2.6 Pressure
setting ...........................................................................
............. 319
3.2.7 Pressure setting for manual pumps without pressure
limiting valve ......... 320
3.2.8 Pressure
connection ........................................................................
......... 320
3.2.9 Pressure
Accumulation ......................................................................
....... 321
3.2.10 Positioning of
Nut ...............................................................................
....... 322
3.2.11 Uncoupling the bolt-tensioning
cylinder .................................................... 322
3.3 Loosening of
bolts..............................................................................
.................... 323
3.3.1 Thread
projection ........................................................................
.............. 323
3.3.2 Adjusting
ring ..............................................................................
.............. 324
3.3.3 Screwing cylinder into
position.................................................................. 325
3.3.4 Pressure
setting ...........................................................................
............. 326
3.3.5 Pressure
Connection.........................................................................
........ 328
3.3.6 Pressure
accumulation.......................................................................
....... 328
3.3.7 Loosening the
nut................................................................................
...... 329
3.3.8 Stiffness in Loosening
Nut ........................................................................ 330
3.3.9 Uncoupling the Bolt-Tensioning
Cylinder .................................................. 331
3.4 Changing the Seal on Bolt - Tensioning Cylinders 3rd generation
(order-no.
33.20xxx) .........................................................................
...................................... 332
3.4.1 Changing the seal in cylinders with piston
return...................................... 332
3.5 Changing the Seal on Bolt - Tensioning Cylinders 5th generation
(order-no.
33.40xxx) .........................................................................
...................................... 334
3.5.1 Changing the seal in cylinders with piston
return...................................... 334
3.5.2 Replacement of Change
Bushing ............................................................. 335
3.6 Determining Tensioning
Force..............................................................................
. 336
3.6.1 Log book for cycle
numbers: ..................................................................... 338
3.7 Operating Instructions in
Brief .............................................................................
.. 339
3.7.1 Prevention of Accidents and
Damage....................................................... 339
3.7.2
Tightening ........................................................................
......................... 339
3.7.3
Loosening..........................................................................
........................ 340
4 Datasheets for bolt-tensioning
cylinder ..........................................................................
................... 341
5 Datasheets for high-pressure pump
unit ..............................................................................
............. 342
6 ACCESSORIES AND SPARE
PARTS..............................................................................
................ 343
290 HTGD 693 000 V0140 A

en
MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
Figures
Fig. 1-1 Schematic diagram hydraulic tensioning

device........................................................... 295
Fig. 2-1 Operating
instructions.......................................................................
............................ 296
Fig. 2-2 Thread
projection.........................................................................
................................. 297
Fig. 2-3 Angular
accuracy...........................................................................
............................... 297
Fig. 2-4:
Lubricaci�n .......................................................................
........................................... 298
Fig. 2-5 ITH-bolt tensioning cylinder
series ............................................................................
... 299
Fig. 2-6 Checking correct position of
piston.............................................................................
.. 300
Fig. 2-7 Application of pressure only when screwed
down........................................................ 301
Fig. 2-8 Do not apply bending stress to
hose ............................................................................
301
Fig. 2-9 Coupling
elbow .............................................................................
................................ 302
Fig. 2-10 Electric high pressure pump
unit ..............................................................................
.. 302
Fig. 2-11 Manual high-pressure pump
unit ..............................................................................
.. 303
Fig. 2-12 Safety distance for work with ITH bolt-tensioning
cylinders ....................................... 303
unit ..............................................................................
.. 304
unit ..............................................................................
.. 304
Fig. 2-15 Never use a damaged pressure
hose. ....................................................................... 305
Fig. 2-16 Test pressure
gauge..............................................................................
..................... 306
Fig. 2-17 Operating pressure for ITH bolt-tensioning
cylinders ................................................. 306
Fig. 2-18 Safety distance when working with ITH bolt-tensioning
cylinders .............................. 307
Fig. 2-19 Max. stroke for ITH bolt-tensioning
cylinders ............................................................. 308
Fig. 2-20 Storage of ITH-bolt tensioning
cylinders..................................................................... 309
Fig. 3-1 Operating
instruction .......................................................................
............................. 309
Fig. 3-2 Safety distance for work with ITH bolt-tensioning
cylinders ......................................... 310
Fig. 3-3
Settling...........................................................................
............................................... 310
Fig. 3-4 Checking correct position of
piston.............................................................................
.. 311
Fig. 3-5 Determining tensioning force, operating
pressure........................................................ 312
Fig. 3-6 ITH-bolt tensioning cylinder
series ............................................................................
... 314
en HTGD 693 000 V0140 A

291
WP4110 & WP4140
Fig. 3-7 Thread

projection ........................................................................
................................. 315
Fig. 3-8 Adjusting ring on round
nut ...............................................................................
........... 316
Fig. 3-9 Counter-tightening round
nut................................................................................
........ 317
Fig. 3-10 Marking of bolt and
ring...............................................................................
............... 317
Fig. 3-11 Checking the
bolt...............................................................................
......................... 318
unit ..............................................................................
.. 319
unit...............................................................................
. 320
Fig. 3-14 Pressure
connection.........................................................................
.......................... 320
Fig. 3-15 Pressure
accumulation.......................................................................
........................ 321
Fig. 3-16 Positioning of
nut................................................................................
........................ 322
Fig. 3-17 Do not uncouple the ITH bolt-tensioning cylinder until the change bushing
is
level with the
cover..............................................................................
............................. 322
Fig. 3-18 Thread
projection ........................................................................
............................... 323
Fig. 3-19 Countertightening of round
nut................................................................................
... 324
Fig. 3-20 Screwing the ITH bolt-tensioning cylinders
into ......................................................... 325
unit ..............................................................................
.. 326
unit...............................................................................
. 327
Fig. 3-23 Pressure
connection.........................................................................
.......................... 328
Fig. 3-24 Pressure
accumulation.......................................................................
........................ 328
Fig. 3-25 Loosening the
nut................................................................................
....................... 329
Fig. 3-26 Loosing a stiff
nut ...............................................................................
........................ 330
Fig. 3-27 Uncoupling the bolt-tensioning
cylinder...................................................................... 331
Fig. 3-28 Dismantling the bolt- tensioning
cylinder.................................................................... 332
Fig. 3-29 Position of seal when
dismantled ........................................................................
....... 333
Fig. 3-30 Position of seal when
reassembling ......................................................................
..... 333
Fig. 3-31 Dismantling the bolt- tensioning
cylinder.................................................................... 334
Fig. 3-32 Replacing the change
bushing ...........................................................................
........ 335
Fig. 3-33 Finding out
tensionworth ......................................................................
...................... 336
Fig. 6-1 ACCESSORIES AND SPARE
PARTS ...................................................................... 343
292 HTGD 693 000 V0140 A

en
MA -
HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
Datasheets of bolt tension cylinders (1100 bar and 1500 bar)
Datasheets of high pressure pump units (1100 bar and 1500 bar)
en HTGD 693 000 V0140 A

293
1 SCHEMATIC DIAGRAM: HYDRAULIC TENSIONING DEVICE
Legend to Fig. 1-1 Schematic diagram hydraulic tensioning device

High pressure hose line Hochdruckschlauchleitung
Order-No. Bestell-Nr.
for coupling kuppelbar
Screw tensioning cylinder Schraubenspannzylinder
as per offer bzw. Datenblatt
Hand lever high pressure pump unit Handhebel-Hochdruckpumpen-
Aggregat
with pressure limitation valve mit Druckbegrenzungsventil
Electric-high pressure pump unit Elektro-Hochdruckpumpen-
Aggregat
Pneumatic-high pressure pump unit Pneumatik-Hochdruckpumpen-
Aggregat
monophase einphasig
294 HTGD 693 000 V0140 A

en
MA - HTGD691538V0005A
-
ITH Bolt-
Tension
Equipment
Fig. 1-1 Schematic diagram hydraulic tensioning device
en HTGD 693 000 V0140 A

295
2 PREVENTION OF ACCIDENTS AND DAMAGE TO EQUIPMENT

2.1 Bolt-Tensioning Cylinder
2.1.1 Operating data
Brief
Operating
Instruction
Bedienungs-
anleitung
10.9
ITH
Fig. 2-1 Operating instructions
CAUTION
Study these operating instructions carefully before beginning
work, and
observe the notes on prevention of accidents and damage to
property.
Check the operating data of the bolt-tensioning cylinder (pre-
tensioning
force, operating pressure) and the bolt (quality, thread length
above nut).
The user is responsible for defining the characteristics of the
bolt, the pre-
tensioning forces and the design of the joint.
If required, ITH-GmbH is available for consultation.
296 HTGD 693 000 V0140 A

en
MA -
HTGD691538V0005A -
ITH Bolt-Tension
Equipment
2.1.2 Thread projection
Fig. 2-2 Thread projection
CAUTION
Before screwing the bolt-tensioning cylinder onto the bolt,
ensure that
there is sufficient thread projection above the nut.
In general, the amount of thread projection above the nut should be
(H) 0.8-1 x M (i.e. for M 100, H = 80 - 100 mm).
Thread H Thread H
M 42x4.5 57 M 90x6 95
M 48x5 60 M 100x6
100
M 56x5.5 67 M 110x6
110
M 64x6 70 M 125x8
125
M 72x6 83 M 140x8
135
M 80x6 90 M 160x8
155
2.1.3 Angular accuracy
machined
surface
X�
X: tolerance of position
Fig. 2-3 Angular accuracy
en HTGD 693 000 V0140 A

297
CAUTION
Check the angle of bolt to the supporting surface and if necessary
correct
it.
2.1.4 Bolt preparation
Fig. 2-4: Lubricaci�n
Lubrication
Before using the bolt-tensioning cylinder, grease the thread of

the bolt.
The grease quality is determined by the user.
298 HTGD 693 000 V0140 A

en
MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
2.1.5 Maximum number of cycles
Tragvorrichtung
dreh- und klappbar
M100/M125
carring handle
swivelling and collapsible
Sicherheitsdeckel
safety cover
Kolbenr�ckstellung
piston return SW
1054
�D1
mountindimension
Einbauma� H2
change bushing GmbH
Postfach 1365
Bruchsicherung 59872 Meschede
order no. ...........
fracture safety device fabric no. ..........
H1
H6
M.
H5
5
H7
H4
H8
H3
Bohrungen zum Anschlagen

der Mutter
St�tzh�lse abnehmbar
�D3
Stempelung
Kontrollnut
�D2
control nut
removable
Fig. 2-5 ITH-bolt tensioning cylinder series
en HTGD 693 000 V0140 A

299
CAUTION
Highly stressed components must be replaces after a certain number
of
cycles. This applies in particular to the change bushing of the
bolt-
tensioning cylinder. Compliance with the specified pressure
(maximum
operating pressure - see Technical Data Sheet) is essential for
achieving
the guaranteed number of cycles.
The maximum number of cycles depends on the effective pre-
tensioning
force, the size of the thread and several other operating
parameters. If re-
quired, ITH will be pleased to state the maximum number of cycles.
The
number of cycles executed must be entered in the data-sheet log
book.
2.1.6 Piston return

change bushing
red marking
10
cover
Fig. 2-6 Checking correct position of piston
CAUTION
Before beginning work, ensure that the piston is in its end
position (i.e. the
change bushing is level with the cover). If the bolt-tensioning
cylinder is
not fitted with an automatic piston return, the piston must be
pressed back
manually into its end position.
300 HTGD 693 000 V0140 A

en
MA -
HTGD691538V0005A -
ITH Bolt-Tension
Equipment
2.1.7 Using the bolt-tensioning cylinder
h.p. coupl. nipple
hose line
Fig. 2-7 Application of pressure only when screwed down
WARNING
Pressure hazard
Do not apply pressure to the bolt-tensioning cylinder until it is
firmly
screwed down onto the bolt.
2.1.8 Bending stresses
Fig. 2-8 Do not apply bending stress to hose
CAUTION
During pressure generation, ensure that the hose, the high-
pressure cou-
pling nipple and the couplings are not subjected to bending
stresses, how-
ever small (Fig. 2-8)
If necessary, use the ITH high-pressure coupling elbow.
en HTGD 693 000 V0140 A

301
Fig. 2-9 Coupling elbow
2.2 High pressure pump units
2.2.1 Electrical installation

1 On-Off-level (Tippfunction) 3 Stop valve
2 Pressure limit valve
Fig. 2-10 Electric high pressure pump unit
CAUTION
Before starting up, ensure that the voltage and frequency of the
power
supply comply with the voltage and frequency of the motor.
For electrical connenction, always comply with the VDE guidelines.
The
electrical components should be checked only by qualified
electriciance.
Before carrying out maintenance work, the system must be
disconnected
from the power supply.
302 HTGD 693 000 V0140 A

en
MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
2.2.2 Pumps with pressure adjusting valve
Pos Designation Pos

Designation
1 Stop valve
Fig. 2-11 Manual high-pressure pump unit
CAUTION
After work, the pressure-control valve (if installed) must be
screwed back
completely (this releases the tension in the pressure spring).
2.3 Pumps with connected cylinder
3-5 m
Schraubenspannzylinder
bolt tensioning cylinder
Elektro-
Hochdruck-Aggregat
electric high
pressure pump unit
Handhebel-
Hochdruckpumpen-Aggregat
hand lever high
pressure pump unit
Fig. 2-12 Safety distance for work with ITH bolt-tensioning cylinders
en HTGD 693 000 V0140 A

303
CAUTION
Important:
Never pressurise the pump when the bolt-tensioning cylinder is
coupled to
it but is not mounted on a bolted joint.
2.4 Prolonging life of the pumps


1 Stop valve
304 HTGD 693 000 V0140 A

en
MA -
HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
CAUTION
In order to prolong the life of the pumps, the following oil change
schedule
is recommended
The first oil change should be performed after 500 working hours.
Each
further oil change should be performed after 5000 working hours,
but
minimal one time per year!
2.5 Hose line
2.5.1 Damage to high-pressure hose line
Fig. 2-15 Never use a damaged pressure hose.
CAUTION
Before using the high-pressure hose, ensure that it is not damaged
or
kinked. Never use damaged of defective hoses. Never work with a
hose
which is kinked. The minimum bending radius is 250 mm.
en HTGD 693 000 V0140 A

305
2.5.2 Test Pressure Gauge for All Units
800
700
900
600
1000
1100
500
400
1200
300
1300
200
1400
100
1500
bar
1600
Kl.1,0
Fig. 2-16 Test pressure gauge
CAUTION
Before using hydraulic units of any kind, use the ITH test gauge
to check
the deviation of the unit in question. The maximum deviation is 1%
of the
maximum value (e.g. 16 bar for maximum pressure of 1600 bar).
2.5.3 Operating pressure
800
700
900
600
1000
500
1100
400
1200
300
1300
200
1400
100
1500
bar
1600
Kl.1,0
Fig. 2-17 Operating pressure for ITH bolt-tensioning cylinders
306 HTGD 693 000 V0140 A

en
MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
CAUTION
General rule:
Never exceed the maximum operating pressure of the bolt-tensioning
cyl-
inder. The maximum operating pressure is stated in the dimensional
draw-
ing.
2.5.4 Safety distance
3-5 m
Elektro-
Hochdruck-Aggregat
electric high
pressure pump unit
Handhebel-
hand lever high
pressure pump unit
Fig. 2-18 Safety distance when working with ITH bolt-tensioning cylinders
WARNING
Pressure hazard
During the pressure-generating process, always remain at a
dis-
tance of 3 - 5 metres from the bolt-tensioning cylinder.
Never stand
in front of the unit in the direction in which the
tensioning force is be-
ing applied. The rise in the hydraulic pressure must be
carefully
monitored by the operating personnel (observe pressure
gauge). If
the pressure does not seem to rise even during continuous
pressure
generation, stop pressure generation immediately. This
symptom
may indicate warping or deformation. For this reason, it is
essential
to check the shape and dimensional accuracy of the bolt and
joint.
en HTGD 693 000 V0140 A

307
2.5.5 Stroke
red marking
10
Fig. 2-19 Max. stroke for ITH bolt-tensioning cylinders
CAUTION
The bolt-tensioning cylinders must never exceed their maximum
stroke.
With the exception of special types, this is usually 10 mm. When
the
maximum stroke is achieved, a red mark is visible on the change
bushing.
If the bolt-tensioning cylinder is operated above its maximum
stroke, it is
no longer capable of functioning.
2.5.6 General safety instructions
When working with hydraulic bolt-tensioning cylinders, always

observe the
general regulations for accident prevention. When the bolt-
tensioning cyl-
inder is under high pressure, never stand in front of it in the
direction of the
tensioning force. The application of pressure must be kept to a
minimum.
Carry out the work as quickly as possible while the system is
under pres-
sure. The pressure must always be released when the system is not
under
supervision. Under no circumstances should the customer make
altera-
tions or modifications to the tools without the written approval
of the manu-
facturer. Safety measures are dependant on the application and are
the
responsibility of the user.
Always wear safety goggles when working with hydraulic equipment.
Al-
ways protect your eyes!
308 HTGD 693 000 V0140 A

en
MA -
HTGD691538V0005A -
ITH Bolt-Tension
Equipment
2.5.7 Storage
Dry climatized storage is essential for the perfect functioning of the
unit.
t=20�C
Fig. 2-20 Storage of ITH-bolt tensioning cylinders
3 OPERATING INSTRUCTION
3.1 Before Using the Bolt-Tensioning Cylinder
3.1.1 Operating instructions
Brief
Operating
Instruction
Bedienungs-
anleitung
10.9
ITH
Fig. 3-1 Operating instruction
CAUTION
Study these operating instructions carefully before beginning
work, and
observe the notes on prevention of accidents and damage to
property.
Check the operating data of the bolt-tensioning cylinder (pre-
tensioning
force, operating pressure) and the bolt (quality, thread length
above nut).
en HTGD 693 000 V0140 A

309
3.1.2 Positioning the unit
3-5 m
Elektro-
Hochdruck-Aggregat
electric high
pressure pump unit
Handhebel-
hand lever high
pressure pump unit
Fig. 3-2 Safety distance for work with ITH bolt-tensioning cylinders
WARNING
Pressure hazard
Always position the unit in such a way that the pressure
gauge and
bolt can be observed during operation.
Safety distance during pressure generation: 3 - 5 metres.
3.1.3 Settling
Bolt-
tension cylinder
round nut
headless
screw
DMS
digital measuring
ampilfier
00001
Fig. 3-3 Settling
310 HTGD 693 000 V0140 A

en
MA
- HTGD691538V0005A -
ITH Bolt-Tension
Equipment
CAUTION
Before tensioning bolts, carry out tests to determine the settling
behavior
of the bolted joint. This applies especially for highly stressed
joints (e.g.
short bolts with high residual tensioning forces). Depending on
the joint in
question, the settling value may be between 1.05 and 1.3.
Measurements
and tests can be carried out in collaboration with ITH.
3.1.4 Piston return
change bushing
red marking
10
cover
Fig. 3-4 Checking correct position of piston
CAUTION
Before beginning work, ensure that the piston is in its end
position (i.e.
change bushing is level with the cover). If the bolt-tensioning
cylinder is
not fitted with an automatic piston return, the piston must be
pressed back
manually into its end position.
en HTGD 693 000 V0140 A

311
OPERATION
& MAINTENANCE BOOK WP4110 & WP4140
3.1.5 Determining tensioning force, operating pressure
Pressure- and tensionworth

Druck- und Spannungswerte
1100 3250,1 Von der

aufgef�hrten Spannkraft ist die R�ckstellkraft (Federpakete) abzu-
1050 3102,4 ziehen.
Diese Kraft ist von dem jeweiligen Zylinderhub abh�ngig. Sie beginnt
bei 2,1 kN
und steigt linear je mm Hub um 1,8 kN bis auf 20,1 kN.
1000 2954,7
Alle Werte
wurden rechnerisch ermittelt.
950 2806,9
900 2659,2 Indicated
tensioning force is to be reduced by restoring force of spring de-
850 2511,5 pending on
cylinder stroke, starting at 2,1 kN and increasing linear per mm
800 2363,7 stroke by
1,8 kN up to 20,1 kN.
All values
are calculated.
750 2216,0
700 2068,3
650 1920,5
600 1772,8
Spannkraftermittlung (tension ascertainment)
550 1625,1
500 1477,3
450 1329,6
400 1181,9
350 1034,1
300 886,4
250 738,7
200 590,9
150 443,2
100 295,5
50 147,7
pressure Druck Tension Spannkraft
in bar in kN
1100
Pressure in bar
1000
900
800
700
600
Betriebsdruck in bar
500
400
300
200
100
0
0 400
800 1200 1600 2000 2400 2800 3250
Spannkraft in kN Tension in kN
Fig. 3-5 Determining tensioning force, operating pressure
312 HTGD 693

000 V0140 A en
MA - HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
CAUTION
The operating pressure (P) for the bolt-tensioning cylinder and the pre-
tensioning force for the bolt are calculated as follows.
P (bar) x A (mm) 2
F (kN) =
1000
F (kN)
P (bar) = 1000 �
A (mm) 2
P = operating pressure of bolt- tensioning cylinder in bar

F = pre-tensioning force of bolt incl. factor for settling loss in kN
A = piston surface of bolt-tensioning cylinder in mm�
(see technical data sheet)
en HTGD 693 000 V0140 A 313

WP4140
3.1.6 Maximum number of load cycles
Tragvorrichtung
dreh- und klappbar
M100/M125
carring handle
swivelling and collapsible
Sicherheitsdeckel
safety cover
Kolbenr�ckstellung
piston return SW
1054
�D1
mountindimension
Einbauma� H2
change bushing GmbH
Postfach 1365
Bruchsicherung 59872 Meschede
order no. ...........
fracture safety device fabric no. ..........
H1
H6
M.
H5
5
H7
H4
H8
H3
Bohrungen zum Anschlagen

der Mutter
St�tzh�lse abnehmbar
�D3
Stempelung
Kontrollnut
�D2
control nut
removable
Fig. 3-6 ITH-bolt tensioning cylinder series
314 HTGD 693 000 V0140 A

en
MA -
HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
CAUTION
Highly stressed components must be replaced after a certain number
of
cycles. This applies in particular to the change bushing of the
bolt-
tensioning cylinder. Compliance with the specified pressure
(maximum
operating pressure - see Technical Data Sheet) is essential for
achieving
the guaranteed number of cycles. Before beginning work, use the
test
handbook (see section datasheet) to verify whether the cylinder
has al-
ready completed the maximum number of 2000 cycles, or will achieve
the
maximum number during this use. This can also be verified by
reading the
automatic cycle counter. The above figure applies only for the
maximum
thread size at maximum tensioning force (1-97). (1 cycle =
pressure build-
up + holding time + pressure release). If this is the case, the
bolt-
tensioning cylinder must not be used until the change bushing has
been
replaced.
3.2 Tightening of Bolts
CAUTION
Before screwing the bolt-tensioning cylinder onto the bolt, ensure
that
en HTGD 693 000 V0140 A
315

(H) 0.8-1 x M (i.e. for M 100, H = 80 - 100 mm).
Thread H Thread H
M 42x4.5 57 M 90x6 95
M 48x5 60 M 100x6 100
M 56x5.5 67 M 110x6 110
M 64x6 70 M 125x8 125
M 72x6 83 M 140x8 135
M 80x6 90 M 160x8 155
3.2.2 Adjusting ring
adjusting ring
driver
Fig. 3-8 Adjusting ring on round nut
CAUTION
Lay the adjusting ring on the nut and insert the pin into the
hole in the front
of the nut.
316 HTGD 693 000 V0140 A

en
MA -
HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
3.2.3 Counter-tightening
Fig. 3-9 Counter-tightening round nut
CAUTION
Once the correct thread projection has been set, turn the nut
down to the
surface. This prevents the bolt from screwing inwards when the
bolt-
tensioning cylinder is being screwed into position.
3.2.4 Bolt on
Fig. 3-10 Marking of bolt and ring
en HTGD 693 000 V0140 A

317
CAUTION
Screw the bolt-tensioning cylinder onto the bolt using the Allen
key or a
ratchet.
From thread size M 100, the bolt-tensioning cylinder should be
suspended
by a spring from a crane.
3.2.5 Checking
marking
lamp
marking
nut not twisted nut twisted
Fig. 3-11 Checking the bolt
CAUTION
After the bolt-tensioning cylinder has been screwed into position,
use the
special torch to check the mark and ensure that the bolt has not
been
screwed further into the housing. The tolerance is approx. 20 -
30�.
If so, the bolt must be removed and the process repeated.
318 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH
Bolt-Tension
Equipment
3.2.6 Pressure setting

Pressure setting for electric and manual pumps with pressure limiting valve

CAUTION
The bolt-tensioning cylinder should not yet be connected to the
motor unit.
- Close the stop valve
- Switch the unit on in step mode
- Screw the pressure limitation valve in until the desired
pressure is ob-
tained
- Switch unit off
- Open stop valve
Important:
the previously determined pressure must not be exceeded.
en HTGD 693 000 V0140 A

319
3.2.7 Pressure setting for manual pumps without pressure limiting valve

1 Stop valve
CAUTION
Screw the bolt-tensioning cylinder onto the bolt until it is hand
tight against
the support surface.
- Connect the bolt-tensioning cylinder and the pump with the high-
pressure
hose
- Generate the previously determined pressure
Important:
the previously determined pressure must not be exceeded.
3.2.8 Pressure connection
h.p. coupl. nipple
hose line
Fig. 3-14 Pressure connection
320 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH Bolt-Tension
Equipment
WARNING
Pressure hazard
Connect the bolt-tensioning cylinder and the pump with the high-
pressure hose
Generate the previously determined pressure
Important:
Do not stand in the tensioning direction of the cylinder!
Do not stand in the axial direction of the hose!
During pressure build-up, observe a safety distance of 3-5 metres.
3.2.9 Pressure Accumulation

change bushing
10
red marking
Fig. 3-15 Pressure accumulation
WARNING
Pressure hazard
Generate the previously set/determined pressure
Never exceed the maximum stroke (generally 10 mm) which is
indicated by the red groove on the change bushing.
If the pressure indicated on the gauge does not increase even
during continuous pressure generation, release the pressure,
remove the bolt-tensioning cylinder and check the joint for
warping or deformation.
en HTGD 693 000 V0140 A

321
3.2.10 Positioning of Nut
opening for
readjustment
adjusting
ring
stick
control nut
Fig. 3-16 Positioning of nut
CAUTION
Once the desired hydraulic pressure has been reached (see section
3.1.5)
switch the unit off. Using the adjusting ring and pin, screw the
nut onto the
support surface. Repeat this process until the nut can be
adjusted no fur-
ther.
3.2.11 Uncoupling the bolt-tensioning cylinder

change bushing
10
red marking
Fig. 3-17 Do not uncouple the ITH bolt-tensioning cylinder until the
change bushing
is level with the cover
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MA -
HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
CAUTION
Open the stop valve on the pump unit. Do not uncouple the hose
until the
piston is in its end position (i.e. change bushing is level with
cover).
For 150 MPa serie:
After opening the shut oft valve at the pump unit, change bushing
has to
be tightened in min. 90� (right direction) with the hexagon socket
wrench
or manual ratchet.
3.3 Loosening of bolts
CAUTION
Before screwing the bolt-tensioning cylinder onto the bolt, ensure
that
en HTGD 693 000 V0140 A

323

(H) 0.8-1 x M (i.e. for M 100, H = 80 - 100 mm).
Thread H Thread H
M 42x4.5 57 M 90x6 95
M 48x5 60 M 100x6 100
M 56x5.5 67 M 110x6 110
M 64x6 70 M 125x8 125
M 72x6 83 M 140x8 135
M 80x6 90 M 160x8 155
3.3.2 Adjusting ring
adjusting ring
driver
Fig. 3-19 Countertightening of round nut
CAUTION
Lay the adjusting ring on the nut and insert the driver pin into
the hole in
the front of the nut.
324 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH
Bolt-Tension
Equipment
3.3.3 Screwing cylinder into position
Spiel
Fig. 3-20 Screwing the ITH bolt-tensioning cylinders into
CAUTION
Screw the bolt-tensioning cylinder onto the bolt using the Allen
key or a
ratchet. For bolts with a length of 1000 mm, there must be a
clearance of
approx. 2 - 3 mm between the support surface and the bolt-
tensioning cyl-
inder. For bolts longer than 1000 mm, the clearance must be
correspond-
ingly greater.
en HTGD 693 000 V0140 A

325
3.3.4 Pressure setting

Pressure setting for electric with pressure limiting valve

CAUTION
The bolt-tensioning cylinder should not yet be connected to the
motor unit.
- Switch the unit on in step mode
- Screw the pressure limitation valve in until the desired
pressure is ob-
tained
- Switch unit off
- Open stop valve
Important:
The previously determined pressure must not be exceeded.
326 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
Pressure setting for manual pumps without pressure limiting valve

1 Stop valve
CAUTION
Screw the bolt-tensioning cylinder onto the bolt until it is hand
tight against
the support surface.
- Connect the bolt-tensioning cylinder and the pump with the high-
pressure
hose
- Generate the previously determined pressure
Important:
The previously determined pressure must not be exceeded.
en HTGD 693 000 V0140 A

327
3.3.5 Pressure Connection
h.p. coupl. nipple
hose line
Fig. 3-23 Pressure connection
WARNING
Pressure hazard
Connect the bolt-tensioning cylinder and the pump with the high-
pressure hose
Generate the previously determined pressure
Important:
Do not stand in the tensioning direction of the cylinder!
Do not stand in the axial direction of the hose!
During pressure build-up, observe a safety distance of 3-5 metres.
3.3.6 Pressure accumulation

change bushing
10
red marking
Fig. 3-24 Pressure accumulation
328 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH
Bolt-Tension
Equipment
WARNING
Pressure hazard
Generate the previously set/determined pressure
Never exceed the maximum stroke (generally 10 mm) which is
indicated by the red groove on the change bushing.
If the pressure indicated on the gauge does not increase
even
during continuous pressure generation, release the pressure,
remove the bolt-tensioning cylinder and check the joint for
warping or deformation.
3.3.7 Loosening the nut
opening for
readjustment
adjusting
ring
stick
control nut
Fig. 3-25 Loosening the nut
Once the hydraulic pressure has been reached (see section 3.1.5),
switch
the unit off. Turn the nut away from the surface by turning the
adjusting
ring with the assistance of the pin provided. For bolts up to 1000
mm in
length, approx. 2 - 3 mm. Observe the turning of the nut in the
control
groove.
After opening the shut of valve at the pump unit, change bushing
has to be
turned in approx. 5� with the hexagon socket wrench or manual
ratchet.
en HTGD 693 000 V0140 A
329
3.3.8 Stiffness in Loosening Nut
F max. at 1100 bar
cooper
mandrel
Fig. 3-26 Loosing a stiff nut
CAUTION
In spite of the application of maximum pressure (see technical
data sheet),
if it is not possible to screw the nut away from the surface,
insert a copper
pin through the two holes in the support sleeve and strike it with
a ham-
mer.
This releases the contact corrosion between the thread and the
surface.
This must be done when the bolt-tensioning cylinder is subjected
to maxi-
mum pressure (see technical data sheet).
330 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH Bolt-Tension
Equipment
3.3.9 Uncoupling the Bolt-Tensioning Cylinder

change bushing
10
red
marking
Fig. 3-27 Uncoupling the bolt-tensioning cylinder
CAUTION
Opening the stop valve on the pump unit completely. Do not remove
the
hose from the cylinder until the piston has reached it's end
position
(change bushing has disappeared into the cover).
For 150 MPa serie:
After opening the shut oft valve at the pump unit, change bushing
has to
be tightened in min. 90� (right direction) with the hexagon socket
wrench
or manual ratchet.
en HTGD 693 000 V0140 A

331
3.4 Changing the Seal on Bolt - Tensioning Cylinders 3rd genera-

tion (order-no. 33.20xxx)
3.4.1 Changing the seal in cylinders with piston return

(using example of a two-stage cylinder; single and multiple-stage cylinder
are simi-
lar)
two hole turner

cover
spring plates
first spring plate
change bushing
piston II
cylinder II
piston I
cylinder I
cycle counter
pressure connection 04
25
h.p. couple nipple

h.p. sealing
screw
Fig. 3-28 Dismantling the bolt- tensioning cylinder
332 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH Bolt-Tension
Equipment
Clamp the bolt-tensioning cylinder into the vice at pressure connection or

cylinder
stage 1. Screw hexagon bolt out of support sleeve and screw support sleeve
off.
Screw off cover with pin-type face spanner. Remove spring packages (cauton:
first
spring in cylinder is hollow; other springs in simple alternating layers - see
Fig. 3-28)
Remove the set screws from the counter nut and then screw counter nut off
change
bush. Loosen countersunk screw on the support sleeve and screw support sleeve
off
cylinder stage 1. Remove change bush. Remove pressure connection or high pres-
sure coupling nippel directly (depending on type). Screw one screw into
threaded
hole of cylinder stage 1 and cylinder stage 2 and the other cylinder stages.
With a
plastic-headed hammer, knock lightly against the screw of cylinder stage 2
until cyl-
inder stage 2 can be removed manually from cylinder stage 1. Proceed in the
same
way with the other cylinder stages. Knock the piston out of the cylinder with
the plas-
tic headed hammer.
Remove used seals. Clean all parts thoroughly. Place new seals on piston and
cylin-
der. Oil piston and cylinder lightly. Place the piston diagonally on the
cylinder and
knock it straight into the cylinder with the plastic hammer. (Caution: there
is a dan-
ger of seizures if the piston is not introduced correctly into the small
diameter).
Continue assembly in the opposite order to dismnatling.
seal position by disassemble
piston
seal ring
sealing
Fig. 3-29 Position of seal when dismantled
seal position by assemble
seal ring piston

sealing
Fig. 3-30 Position of seal when reassembling
en HTGD 693 000 V0140 A

333
3.5 Changing the Seal on Bolt - Tensioning Cylinders 5th genera-

tion (order-no. 33.40xxx)
3.5.1 Changing the seal in cylinders with piston return

(using example of a two-stage cylinder; single and multiple-stage cylinder
are simi-
lar)
two hole turner

cover
spring plates
first spring plate
change bushing
piston II
cylinder II
piston I
cylinder I
cycle counter
pressure connection 04
25
h.p. couple nipple

h.p. sealing
screw
Fig. 3-31 Dismantling the bolt- tensioning cylinder
Clamp the bolt-tensioning cylinder into the vice at pressure connection or

cylinder
stage 1. Screw off cover with pin-type face spanner. Remove spring packages
(cauton: first spring in cylinder is hollow; other springs in simple
alternating layers -
see Fig. 3-31)
334 HTGD 693 000 V0140 A
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MA -
HTGD691538V0005A -
ITH
Bolt-Tension
Equipment
Remove the set screws from the counter nut 2 and screw counter nut off.
Screw
pressure connection off. Screw one screw into threaded hole of cylinder
stage 1 and
cylinder stage 2 and the other cylinder stages. With a plastic-headed
hammer, knock
lightly against the screw of cylinder stage 2 until cylinder stage 2 can be
removed
manually from cylinder stage 1. Remove set screw from counter nut 1 and
screw
counter nut 1off. Remove countersunk screw from the fracture safty ring and
screw
the ring off.
Remove change bush.
Knock the piston out of the cylinder with the plastic headed hammer.
Remove used seals. Clean all parts thoroughly. Place new seals on piston
and cylin-
der. Oil piston and cylinder lightly. Place the piston diagonally on the
cylinder and
knock it straight into the cylinder with the plastic hammer. (Caution:
there is a dan-
ger of seizures if the piston is not introduced correctly into the small
diameter).
Continue assembly in the opposite order to dismnatling.
3.5.2 Replacement of Change Bushing
two hole turner
cover
spring plates
first spring plate
change bushing
04 cycle
25 counter
Fig. 3-32 Replacing the change bushing
Clamp the bolt-tensioning cylinder into the vice by the connection or

cylinder I. Re-
move the cover with the two-hole spanner provided. Remove the spring
package
en HTGD 693 000 V0140 A

335
(Important! the first spring in the cylinder is hollow; thereafter they are
arranged al-
ternately; see diagram Fig. 3-32). Reassemble in reverse order as described
above.
Important! Clean and lightly oil all parts.
3.6 Determining Tensioning Force
800
700 900
600
1000
500
1100
400
1200
300
1300
200
1400
100
1500
bar
1600
Kl.1,0
Fig. 3-33 Finding out tensionworth
The tensioning force (F) of the bolt-tensioning cylinder is directly related

to the pres-
sure. The pressure is indicated in bar by the pressure gauge on the pump
unit. The
tensioning force can be determined using the table in chapter 3.1.5, or
calculated by
means of the following equations.
P (bar) x A (mm) 2
F (kN) =
1000
F
(kN)
P (bar) = 1000 �
A
(mm) 2
tension Force (F) in kN

pressure (P) in bar
piston area (A) in mm2
see technical data sheet for bolt-tension cylinder
336 HTGD 693 000 V0140 A

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MA - HTGD691538V0005A -
ITH Bolt-
Tension
Equipment
Units for Force and Pressure

a) force: SI-unit:
pressure = Newtons per sq. metre (N/m2)
technical unit: bar
convention factor: 1 bar = 1x105 N/m2
1 bar = 1x10-1 N/mm2
1 bar = 1x105 Pa (Pascal)
b) pressure: British unit:
pressure = pounds per square inch (lbf/in2)
convention factor: 1 (lbf/in2) = 6895 (N/m2)
en HTGD 693 000 V0140 A

337
3.6.1 Log book for cycle numbers:

Tool size Manufact-no.
Date Start reading Finish reading Cycles used Total usage Signature
338 HTGD 693 000 V0140 A

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MA -
HTGD691538V0005A -
ITH
Bolt-Tension
Equipment
3.7 Operating Instructions in Brief

Before beginning work, study section 2. thoroughly!
3.7.1 Prevention of Accidents and Damage

a) During the pressure build-up phase, (i.e. before the bolt-tensioning
cylinder has
reached the previously set pressure) always remain at a safe distance
from the
bolt-tensioning cylinder (approx. 3 - 5 metres).
b) Do not screw the bolt-tensioning cylinder onto the bolt until the piston
has
reached its lower end position, i.e. the change bushing is flush with
the cover.
This does not apply to special types.
c) Check the operating data of the bolt-tensioning cylinder and the
specification of
the bolt.
d) Screw the bolt-tensioning cylinder or change bushing far enough onto the
bolt.
e) Dry climatized storage is essential for the perfect functioning of the
unit.
f) Never allow the bolt-tensioning cylinder to exceed the maximum stroke
(generally
10 mm).
g) Operating personnel should never stand in the extended axis of the bolt-
tensioning cylinder. This also applies for other persons in the
vicinity.
For further instructions on the prevention of accidents and

damage, refer
to operating instructions, section 2.
3.7.2 Tightening
a) Screw the bolt-tensioning cylinder onto the bolt until it is hand tight
against the
support surface. (Approximately 30 - 50 Nm). Use the hole in the change
bushing
to check for sufficient depth of penetration.
b) Connect high-pressure hose to bolt-tensioning cylinder and pump unit or
pressure
distributor.
c) Generate the required pressure with the high-pressure pump unit.
d) Tighten the nut on the pressurized joint as far as possible (approx. 60
- 100 Nm).
Observe the turning of the nut in the observation groove.
e) Open the stop valve on the high-pressure pump unit and depressurize the
cylin-
der.
en HTGD 693 000 V0140 A

339
f) Do not close the stop valve until the pistons in the bolt-tensioning
cylinder have
been pressed back into position (this is done by piston-return device if
fitted).
Generate the desired pressure again and try to readjust the nut. Repeat
this
process until the nut can no longer be adjusted.
g) Dismantle the unit in the reverse order.
h) When all the bolts has been tightened, repeat the process on the first
bolt, as the
tightening of the other bolts reduces the load on the first and second
bolts.
3.7.3 Loosening
a) Screw the bolt-tensioning cylinder onto the bolt until a gap of 2-3 mm
remains be-
tween the cylinder and the sup-port surface (applies to bolts up to 1000
mm in
length). If necessary, check the depth of penetration through the hole
in the
change bushing.
b) Connect high-pressure hose to bolt-tensioning cylinder and pump unit or
pressure
distributor.
c) Generate the required pressure with the high-pressure pump unit.
d) Screw the nut on the pressurized joint approximately 2 - 3 mm away from
the
support surface (applies to bolts up to 1000 mm in length). Observe the
turning of
the nut in the observation groove.
e) Open the stop valve on the high-pressure pump unit, depressurize the
cylinder,
and allow the piston to return to its end position.
f) Wait until the piston has reached its end position before uncoupling the
hose or
unscrewing the bolt-tensioning cylinder.
g) For further instructions on tightening and loosening nuts, refer to
operating in-
structions.
For further instructions on the prevention of accidents and

damage, refer
to operating instructions, section 2.
340 HTGD 693 000 V0140 A

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MA - HTGD691538V0005A -
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Equipment
4 DATASHEETS FOR BOLT-TENSIONING CYLINDER

see additional document
Datasheets of bolt tension cylinders (1100 bar and 1500 bar)
en HTGD 693 000 V0140 A 341

5 DATASHEETS FOR HIGH-PRESSURE PUMP UNIT

see additional document
Datasheets of high pressure pump units (1100 bar and 1500 bar)
HTGD691538D0410
342 HTGD 693 000 V0140 A en

MA - HTGD691538V0005A -
ITH Bolt-Tension
Equipment
6 ACCESSORIES AND SPARE PARTS
Fig. 6-1 ACCESSORIES AND SPARE PARTS
HTGD691538V0005
en HTGD 693 000 V0140 A 343

Blank Page
344 HTGD 693 000 V0140 A en

MA - HTGD690148V0001B -
Isolating Valve
MA - HTGD690148V0001B -
Isolating Valve
en HTGD 693 000 V0140 A 345

Revision History
total :
B New format, 98-04-21 -
- - (6)
346 HTGD 693 000 V0140 A en

MA - HTGD690148V0001B -
Isolating Valve
Contents
1
PURPOSE............................................................................
..............................................................349
2 CONSTRUCTION AND PRINCIPLE OF
OPERATION .....................................................................349
en HTGD 693 000 V0140 A

347
WP4110 & WP4140
Figures
Fig. 1 Sectional
view...............................................................................
................................... 350
348 HTGD 693 000 V0140 A

en
MA -
HTGD690148V0001B -
Isolating
Valve
1 PURPOSE
The isolating valve serves as a measuring connection at points where a
continuous
monitoring of pressure is not necessary.
Its design enables the installation or removal of a pressure gauge while the
system is
under pressure. After the removal of the pressure gauge the measuring point
can be
closed leak-tight.
Before the initial start-up and after all maintenance work on the oil system
i.e. ex-
changing of oil, cleaning, modifications install pressure gauges on all oil
test cocks to
ensure that the required oil pressure, necessary for start-up is available.
2 CONSTRUCTION AND PRINCIPLE OF OPERATION

Great emphasis was laid on a compact design of the isolating valve as shown in
Fig.
1.
The housing is a steel casting. At the bottom, it has a threaded pin with
which it is
screwed into the connection point for measurement; it is sealed with gasket 5.
At the top, it has the connection for the measuring equipment and in a lateral
tapped
hole the sealing screw 2. With a screw driver the sealing screw can be turned
permit-
ting the oil to pass.
The connection for the measuring equipment and the bore for the sealing screw
can
be closed oil tight by screw plugs 3, 6 and gaskets 4, 7.
en HTGD 693 000 V0140 A

349

1 Housing 5 Gasket
2 Sealing screw 6 Plug
3 Plug 7 Gasket
4 Gasket 8 O-ring
Fig. 1 Sectional view
HTGD690148V0001B
350 HTGD 693 000 V0140 A en

MA - Illustrated Parts Catalogue
en HTGD 693 000 V0140 A 351

Revision History
total :
- - (108)
352 HTGD 693 000 V0140 A en

Contents
1 Parts
Lists..............................................................................
............................................. 356
1.1 MAA10CT005 - Temperature Sensor -
HTGD800073V0024 ................................ 356
1.2 MAA10CT010 - Temperature Sensor -
HTGD800073V0010 ................................ 358
1.3 MAA12 - Spring Loaded Support -
HTGD800011V0002 ...................................... 360
1.4 MAA12AA001 - Stop Valve -
HTGD800014V0007B.............................................. 362
1.5 MAA12AA001 - Stop Valve Actuator -
HTGD800059V0021.................................. 366
1.6 MAA12AA011 - Control Valve -
HTGD800012V0010............................................ 372
1.7 MAA12AA011 - Control Valve Actuator -
HTGD800040V0026 ............................. 376
1.8 MAA10/MAC10 - High- Low Pressure Turbine -
HTGD800204V0005 .................. 382
1.9 MAA10/MAC10 - High- Low Pressure Turbine Rotor -
HTGD800205V0004......... 404
1.10 MAC10 - Foundation Bolt -
HTGD800035V0012................................................... 406
1.11 MAC10 - Foundation Bolt -
HTGD800035V0013................................................... 408
1.12 MAC31 - Butterfly-Type Valve -
HTGD800007V0004............................................ 410
1.13 MAD20 - Foundation Bolt -
HTGD800035V0010................................................... 430
1.14 MAD20 - Thrust Bearing Pedestal -
HTGD800099V0014 ..................................... 432
1.15 MAD21 - Combined Thrust and Journal Bearing -
HTGD800002V0012 ............... 444
1.16 MAD51 - Pocket-Type Journal Bearing -
HTGD800093V0013.............................. 448
1.17 MAV21AP011 - Gear Pump -
HTGD800047V0011 ............................................... 450
1.18 MAX43 - Trip Unit -
HTGD800032V0003A ............................................................ 452
1.19 MAX44 - Sequence Valve -
HTGD800031V0005B................................................ 454
en HTGD 693 000 V0140 A

353
-
354 HTGD 693 000 V0140 A en

CHAPTER
ILLUSTRATED PARTS LISTS
en HTGD 693 000 V0140 A 355

1 PARTS LISTS
1.1 MAA10CT005 - Temperature Sensor - HTGD800073V0024
Fig.1 Temperature sensor
356 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd TEF96A AX=590 SO=240
Drw-Pos Order- Designation

Qty
Pos
999 TEMPERATURE SENSOR COMPL.
1
1 1 TOGGLE LEVER
1
2 2 THERMOCOUPLE COMPL.TYPE N
1
3 3 SPRING DISK
1
4 4 COMPRESSION SPRING
1
5 5 FLANGE
1
6 6 CONNECTION
1
7 7 EXPANSION STUD M16-TX100
6
8 8 SOCKET HEX NUT M16
6
9 9 GASKET 29/22X1-CU
1
10 10 HEXAGON HEAD-S-PLUG G1/2A ST/ZN
1
11 11 CONNECTION HEAD
1
12 13 HEXAGON HEAD SCREW M10X25 ST460TS
3
13 12 LOCK WASHER 1L 10.5/20X20 ST-NR
3
en HTGD 693 000 V0140 A

357
1.2 MAA10CT010 - Temperature Sensor - HTGD800073V0010
Fig.1 Temperature sensor
358 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd TEF96A AX=710 SO=150

Qty
Pos
999 TEMPERATURE SENSOR COMPLETE
1
1 1 TOGGLE LEVER
1
2 2 THERMOCOUPLE COMPLETE
1
3 3 SPRING DISC
1
1
5 5 FLANGE
1
6 6 CONNECTION
1
7 7 EXPANSION STUD M16-TX100
6
8 8 SOCKET HEXAGON NUT M16
6
9 9 GASKET 29/22X1-CU
1
10 10 HEXAGON HEAD-S-PLUG G1/2A ST/ZN
1
11 11 CONNECTION HEAD
1
12 12 HEXAGON HEAD SCREW M10X25 ST460TS
3
13 13 LOCK WASHER 1L 10.5/20X20 ST-NR
3
en HTGD 693 000 V0140 A

359
1.3 MAA12 - Spring Loaded Support - HTGD800011V0002
Fig.1 Spring loaded support
360 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd

Qty
Pos
999 SPRING LOADED SUPPORT
1
1 1 GUIDE ROD 120X360

1
2 2 GUIDE SLEEVE 160X258
1
3 3 SPHERICAL BEARING AREA 130X250
1
4 4 BOLT 35X206
1
5 5 SWING SUPPORT 130X80
1
6 6 DISC SPRING B 160/82
12
7 7 HEXAGON-S SCREW M24X130/8.8/SW
2
8 8 WASHER:A 25/44 ST/A4G
2
9 9 S-SCREW-I6-FDP M12X30 45H
3
10 10 HEXAGON HEAD SCREW M20X130 8.8
2
11 11 HEXAGON-NUT-0.8D M20 8/ZN
2
12 12 WASHER:A 21/37 ST/ZN
2
en HTGD 693 000 V0140 A

361
1.4 MAA12AA001 - Stop Valve - HTGD800014V0007B
AVBA0201_
Fig.1 Stop Valve
362 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd FD-SSVM 250

Qty
Pos
999 STOP VALVE COMPLETE
1
1 1 INTERMEDIATE PIECE
1
2 2 LOCK
1
3 3 DIFFUSER
1
4 4 SPINDLE
1
5 5 VALVE HEAD
1
6 6 SEGMENT RING 4-PARTS
1
7 7 CLAMPING RING
1
8 8 WELD-IN RING 4
1
9 9 LOCKING RING
1
10 10 GUIDE BUSHING
1
11 11 INSERT COMPLETE
1
12 12 STEAM STRAINER COMPLETE
1
13 13 HEAT SHIELD
2
14 14 SEAL ELEMENT COMPLETE
1
15 15 SEAL
1
16 16 SPEC.-ELONGATION-STUD
12
17 17 COUPLING NUT
1
18 18 CYLINDRICAL PIN
3
19 19 GUIDE BUSHING
1
23 20 HEXAGON NUT
4
24 21 FIXATION PLATE
1
25 22 SQUARE
4
30 23 EXPANSION STUD M24-TKX110
12
31 24 HEXAGON HEAD JACKING SCREW FDP M16-TX70 ST
4
33 25 HEXAGON SCREW M12-TX35 ST-GA
8
35 26 HEXAGON HEAD SCREW M10X16 8.8/ZN
6
37 27 HEXAGON NUT-0.8D,EW M24 ST-GA
12
39 28 LOCK WASHER AN10,5
6
en HTGD 693 000 V0140 A

363
AVBA0201_
Fig.1 Stop Valve
364 HTGD 693 000 V0140 A en

Catalogue

Qty
Pos
40 29 PIN S-SW 8X60 FDST-NR 1
43 30 LOCKWASHER 1L 13/25X20 ST/BK 8
44 31 HEXAGON HEAD S-PLUG G1/2A ST-GA 4
45 32 LOCK WASHER 1L 10.5/20X20 ST/BK 4
46 33 HEXAGON HEAD SCREW M10X20 8.8/ZN 4
en HTGD 693 000 V0140 A

365
1.5 MAA12AA001 - Stop Valve Actuator - HTGD800059V0021
Fig.1 Stop valve actuator
366 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd SSA 200 105

Qty
Pos
999 STOP VALVE ACTUATOR
1
1 1 HOUSING MACHINED
1
2 2 PISTON ROD
1
3 3 VALVE BLOCK COMPLETE
1
4 4 PISTON CROWN
1
5 5 SPRING STOP
1
6 6 INSERT RING
1
7 7 COVER MACHINED
1
8 8 SEAL
1
9 9 ORIFICE D1,2 CENTR.
1
11 10 DISK SPRING
35
14 11 SPACER SLEEVE L=79MM
1
15 12 ALUMINIUM PLATE
1
16 13 PROTECTION CAP
1
17 14 DISCHARCHING PLATE
1
18 15 PROTECTION PLATE
1
19 16 PROTECTION PLATE P.STROKE
1
20 17 COUPLING COVER
1
30 18 LINEAR TRANSMITTER 125MM
1
60 19 3/2-WAY SEAT VALVE SPANNUNG:110V DC
1
65 20 IMPULSE SOLENOID VALVE SPANNUNG:110V DC
1
100 21 GUIDE STRIP 30 X 3
1
1
102 23 SLIDE RING �117/112X3,8
2
103 24 SLIDE RING �200 B5,8 S3
1
104 25 COMPR SPRG 20/2X80 ST
1
105 26 SCREW PLUG G1/2"
1
106 27 SCREW PLUG G1 1/2"
1
1
108 29 SCREW PLUG G1"
1
en HTGD 693 000 V0140 A

367
Fig.1 Stop valve actuator
368 HTGD 693 000 V0140 A en

Catalogue
Drw-Pos Order- Designation Qty

Pos
109 30 BAL-PLUG G 3/8X10 ST 1
110 31 BAL-PLUG G 1/8X10 ST 1
112 32 O-RING 117,1X3,53 2
113 33 RING SEAL 183,52X5,33 G80 1
114 34 STRIPPER 1
115 35 BALL 25 G28-100CR6 1
117 36 HEXAGON S SCREW M6X16 8.8/SW 8
119 38 HEXAGON S SCREW M6X50/8.8/SW 4
125 42 SPR-L-WASHER 6 ST/BK 12
130 46 HEX HD SCR M12X40 8.8/ZN 6
135 47 L-WAS,2L 13/25X45 ST/ZN 3
en HTGD 693 000 V0140 A 369

Fig.2 Valve block
370 HTGD 693 000 V0140 A en

Catalogue

Pos
51 48 VALVE BLOCK - 1
53 49 VALVE BODY 1
55 50 VALVE PLATE 1
57 51 SEAL 1
73 52 CHECK VALVE RC1 1
74 53 COMPR-SPRG 31.5/2.5X50 1
76 54 RING SEAL 31.34X3.53 G80 1
80 57 SPR-L-WASHER 8 ST/BL 4
105 58 SCREW PLUG G1/2" 1
106 59 SCREW PLUG G1 1/2" 1
108 60 SCREW PLUG G1" 1
en HTGD 693 000 V0140 A 371

WP4110 & WP4140
1.6 MAA12AA011 - Control Valve - HTGD800012V0010

29
33 16 24
18 10
33
28
35
14
29
19
31
26
17
28
35
9
8
38
2
16 32
27
3
13
36 22
12
11
15 1
25 7
30
6
5
37
21
4
20
AVEC0201_
Fig.1 Control Valve

372 HTGD 693 000 V0140 A
en
Catalogue
Manufacturer Type
Alstom Power Ltd FD-STVM 200

Qty
Pos
999 CONTROL VALVE COMPL.
1
1
2 2 LOCK
1
3 3 DIFFUSER
1
4 4 VALVE BELL
1
5 5 FLOW BAFFLE
1
6 6 SPINDLE
1
7 7 ELONGATION BUSHING
1
8 8 GUIDE BUSHING
1
9 9 SEAL ELEMENT COMPL
1
10 10 LOCKING RING
1
11 11 SEGMENT RING 4-PARTS
1
12 12 CLAMPING RING
1
13 13 SEAL
1
14 14 BOLT
1
15 15 COUPLING NUT
1
16 16 HEAT SHIELD
2
17 17 DISTANCE SLEEVE
1
18 18 SQUARE
4
19 19 CYLINDRICAL PIN
3
20 20 PISTON RING DN200
2
21 21 TURN LOCK
1
22 22 SPEC.-ELONGATION-STUD
12
24 23 PIN
1
25 24 EXPAN STUD M24-TKX110
12
26 25 H-HD SCR FDP M16-TX80 GA
8
27 26 HEXAGON SCREW M12-TX35 ST-GA
4
en HTGD 693 000 V0140 A

373
WP4110 & WP4140
29
33 16 24
18 10
33
28
35
14
29
19
31
26
17
28
35
9
8
38
2
16 32
27
3
13
36 22
12
11
15 1
25 7
30
6
5
37
21
4
20
AVEC0201_
Fig.1 Control Valve

374 HTGD 693 000 V0140 A
en
Catalogue

Qty
Pos
28 27 HEXAGON SCREW M8-TX16 ST-GA 8
30 29 HEXAGON-NUT T1 M24 GA 12
31 30 HEXAGON-NUT T1 M16 GA 8
32 31 L-WAS,1L 13/25X20 ST/ZN 4
33 32 L-WAS,1L 8.4/18X20 ST/ZN 8
35 33 L.WASHER 1L-8.4X22 ST/A4G 6
36 34 PIN P 8X60 ST/BK 1
37 35 HEXAGON-HEAD SCR FDP M16-TX70 GA 3
38 36 EYE BOLT M16 ST ZN 1
en HTGD 693 000 V0140 A

375
1.7 MAA12AA011 - Control Valve Actuator - HTGD800040V0026
Fig.1 Control valve actuator
376 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd STAE 180100

Qty
Pos
999 CONTROL VALVE ACTUATOR
1
1
2 2 PISTON ROD
1
3 3 VALVE BLOCK COMPLETE
1
4 4 MINI-MEAS.CONNECTOR G1/2"
1
5 5 SPRING STOP
1
6 6 INSERT RING
1
7 7 COVER MACHINED
1
8 8 SEAL
1
9 9 ORIFICE D1,2
1
11 10 BELLEVILLE SPRING
39
14 11 SPACER SLEEVE
1
15 12 ALUMINIUM PLATE
1
16 13 PROTECTION CAP
1
1
20 15 COUPLING SLEEVE
1
1
22 17 THREADED ROD
1
23 18 HELICAL DISK SPRING
1
30 19 LINEAR TRANSMITTER 125MM
1
40 20 AMPLIFIER
1
1
1
102 23 SLIDE RING DIA117/112X3,8
2
103 24 SLIDE RING DIA180 B5,8 S3
1
106 25 SCREW PLUG G1 1/2"
1
1
en HTGD 693 000 V0140 A

377
Fig.1 Control valve actuator
378 HTGD 693 000 V0140 A en

Catalogue

Pos
110 27 O-RING 117,1X3,53 2
111 28 RING SEAL 164,47X5,33 G80 1
112 29 STRIPPER 1
120 35 SPRING LOCKWASHER 6 ST/BK 8
130 39 HEXAGON HEAD SCREW M12X100/8.8/ZN 6
140 40 RE-RG 63X2 FDST 1
145 41 PIN S-SW 6X50 STS 1
en HTGD 693 000 V0140 A 379

Fig.2 Valve block
380 HTGD 693 000 V0140 A en

Catalogue

Pos
52 42 VALVE BLOCK 1
54 43 VALVE BODY 1
56 44 VALVE PLATE 1
57 45 SEAL 1
58 46 GUARD PLATE 1
59 47 DISCHARCHING PLATE 1
65 48 PROPORTIONAL VALVE 1
72 49 CHECK VALVE RVC-16/ESH-25 1
74 50 COMPRESSION SPRING 31.5/2.5X50 1
76 51 RING SEAL 31.34X3.53 G80 1
80 55 SPRING LOCKWASHER 8 ST/BL 8
en HTGD 693 000 V0140 A 381

1.8 MAA10/MAC10 - High- Low Pressure Turbine -

HTGD800204V0005
20
21
23
44
56
12
13
Fig.1 Outer casing, upper half
382 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd MDG100K/1-NE33AA

Qty
Pos
999 TURBINE COMPLETE
1
1 1 IP-OUTER CASING UPPER HALF

1
6 2 ELONG. STUD M64-TK X320
60
7 3 NUT M64
124
8 4 SUPPORT RING D111,5X15
124
12 5 SCREW PLUG M24-T
2
13 6 SEAL RING D34
2
14 7 ELONGAT. STUD M64-TKX420
64
16 8 HEXAGON HEAD SCR FDP M36-TX300 GA
6
17 9 COVERING HOOD 64 COMPL.
64
2
19 11 SEAL RING D77
2
5
21 13 SEAL RING D61
5
23 14 SEAL RING D47
3
44 15 SLEEVE M36-T 200 LG
5
56 16 HEXAGON HEAD-S-PL M18F ST/ZN
5
en HTGD 693 000 V0140 A

383
Fig.2 Outer casing, lower half
384 HTGD 693 000 V0140 A en

Catalogue

Pos
2 17 IP-OUTER CASING LOWER HALF 1
10 18 EXPANSION SLEEVE 48.4 20
18 19 SCREW PLUG M64-T 2
19 20 SEAL RING D77 2
22 22 EXP. STUD SCR M48-TKX280 20
24 23 PROTECTIVE QUARD 20
26 24 SUPPORT DISC 63 2
27 25 SHIM SET DN63 2
28 26 HEXAGON S SCREW M10-TX55/ST-GA 8
31 27 AXIAL KEY 80 4
41 28 TEMPERATURE SENSOR COMPLETE 1
42 29 TEMPERATURE SENSOR COMPLETE 1
45 30 CONNECTION PIECE 1
46 31 CONNECTION PIECE 2
47 32 INTERMEDIATE TUBE 217LONG 2
48 33 GUIDE PIN DIA 105/155 1
51 34 SHIM D 64/13X0,15 14
52 35 COUNTERSINK DISK D71X23 2
53 36 HEXAGON S SCREW M12-TX25 ST-GA 4
55 37 LOCKING BOLT M10-TX20 14
60 39 IP-GL.-CAS. LOWER HALF.D630 MACH. 1
61 40 IP-GL.-CAS. UPPER HALF.D630 MACH. 1
62 41 SPRING D8/1.5X29 12
63 42 CYL.COM SPRING D14/2,5X29 84
64 43 SEAL RING DN630X6.0 SB35-X6-E2-T6 ST330 1
65 44 SEAL RING DN630X7.33 3
en HTGD 693 000 V0140 A

385
386 HTGD 693 000 V0140 A en

Catalogue

Pos
73 45 HEX HD S PL G1 1/2A ST ZN 2
74 46 SEAL RING SB65 2
75 47 SHIM D 64/13X0,2 14
77 48 HEX.SCREW M12X30 W.HOLE 4
78 49 WIRE DR1.5 600
79 50 HEX SKT HEAD CUP NUT M48 20
83 51 LATERAL KEY COMPL. 200 4
en HTGD 693 000 V0140 A 387

Fig.4 Inner casing
388 HTGD 693 000 V0140 A en

Catalogue

Pos
26 53 SUPPORT DISC 63 8
30 55 STEAM SEAL. RINGS DN315 1
80 58 INNER CASING UPPER HALF 1
81 59 INNER CASING LOWER HALF 1
85 60 NUT M80X6 13
87 61 EXP. STUD SCR M80-TKX520 13
88 62 HEXAGON SCREW,DP M36X300-5.6A.G 4
89 63 ELONGAT.STUD M100-TKX560 11
90 64 SUPPORT RING D161,5X20 11
91 65 NUT M100X6 11
92 66 SEAL RING SB65 5
95 67 TAPER PIN 36X450-ST460TS 4
512 68 P PIN 6X25 STS 1
540 69 BOLT 1
542 71 HEXAGON S SCREW M10-TX30 ST-V 2
543 72 LOCKING SCREW M20-T 1
en HTGD 693 000 V0140 A

389
Fig.5 LP Outer casing, upper half
390 HTGD 693 000 V0140 A en


Pos
7 73 NUT M64 20
14 75 ELONGAT. STUD M64-TKX420 4
17 76 COVERING HOOD 64 COMPL. 20
32 78 H-HD SCR FDP M36-TX140 GA 8
44 79 SLEEVE M36-T 200 LG 5
56 80 HEXAGON HEAD SOCKET PLUG M18F ST/ZN 5
66 81 CASING MACHINED CPL. 1
69 82 ELONG. STUD M64-TK X300 6
101 84 EXP.STUD BOLT M64-TKX770 2
102 85 EXP.SLEEVE W.RAIS.FACE 64 4
103 86 HOLDING KEY 47X19X6 4
104 87 TAPER PIN 24X212-ST460TS 8
105 88 RUPTURE DIAPHRAGM COMPL. 1
106 89 RUPTURE DIAPHRAGM SUPPORT 1
107 90 SEAL 1
109 92 HEXAGON S SCREW M36X120/8.8/A4G 90
110 93 PIPELINE FOR WATER INJEC. 1
111 94 SEALING DIA 82/45X1.5 2
112 95 HEXAGON HEAD SCREW M16X55/ 8.8/ZN 4
113 96 HEXAGON NUT 1D M16 8/ZN 4
115 98 SEAL PT2500AF D82/$43X1 1
116 99 ORIFICE D165/$5X8 ORIFICE BORE HOLE 1
117 100 GASKET 107/61X2 3
118 101 WATER INJECTION VALVE 1
120 103 HEXAGON NUT T1 M16 8/ZN 8
en HTGD 693 000 V0140 A 391

577
578 579
120
392 HTGD 693 000 V0140 A en

Catalogue

Pos
7 104 NUT M64 20
17 105 COVERING HOOD 64 COMPL. 64
50 106 VACUUM BREAKER COMPLETE 1
54 107 SPR-L-WASHER 10 ST/BL 14
102 110 EXPANSION SLEEVE W.RAIS.FACE 64 4
120 111 HEXAGON NUT T1 M16 8/ZN 8
121 112 CASING SLIDING ELEMENT 1 PIECE = 1 ELEMENT HALF 12
122 113 CS-SCR,SL M10X20 4.8/ZN 24
132 114 SEAL 1
133 115 COVER 1
135 117 SEAL 1
137 118 PROTECTION PLATE 1
138 119 FULL CONE NOZZLE DIA 4.05MM 10
139 120 ELBOW EWE 12XG3/8A ST 1
140 121 HEXAGON HEAD-S-PL G3/8A-ST/ZN 1
141 122 PRESS TRANSMITTER 3051 TA 3
572 124 GASKET 3
573 125 3/2 BALL COCK,STAINL. DN6 3
575 126 COVER MACH.D650 1
578 128 GASKET 120/75X2 2
579 129 ORIFICE / OUTERD.= DIA 88 1
580 130 COVER 1
en HTGD 693 000 V0140 A

393
WP4140
66
161
32,144
160
109
145
104
32
143
82
142
150 157
571
68
159
144
151
153 71
661
155
156
154 663
152
662
59
147,146 63
150
149,148
72
104, 59
662
64
62
55 55
ACAA0603_
A2098
Fig.7 Bearing casing, details
394 HTGD 693 000 V0140 A

en
Catalogue

Pos
32 132 HEXAGON JACKING SCREW M36-TX140 ST 8
59 134 TAPER PIN 16X160 COMPL. 2
62 135 SPRING D8/1.5X29 12
64 137 SEAL RING DN630X6.0 1
68 139 BEARING BRACKET PREMACH. 1
71 140 POCKET BEARING 315 1
72 141 SEAL RING DN630X6 SB65-X6-E2-T6 ST330 3
104 143 TAPER PIN 24X212-ST460TS 8
109 144 HEXAGON SOCKET SCREW M36X120/8.8/A4G 90
142 145 CYL.SCREW M64X260-CL:12.9 4
143 146 CYLINDRICAL PIN 2
145 148 HEXAGON SCREW DP M16X140 ST/ZN 2
147 150 HEXAGON NUT-0.8D M12 8/ZN 2
149 152 HEXAGON NUT-0.8D M20 8/ZN 8
150 153 GLAND D630 MACHINED 1
151 154 SCRAPER UP MACHINED 1
152 155 SCRAPER LP MACHINED 1
154 157 HEX-S-PLUG G3/8A ST/ZN 2
en HTGD 693 000 V0140 A 395

WP4140
66
161
32,144
160
109
145
104
32
143
82
142
150 157
571
68
159
144
151
153 71
661
155
156
154 663
152
662
59
147,146 63
150
149,148
72
104, 59
662
64
62
55 55
ACAA0603_
A2098
Fig.8 Bearing casing, details
396 HTGD 693 000 V0140 A

en
Catalogue

Qty
Pos
155 158 GASKET 21.9/18.2X1.5 2
156 159 PROFILE 2X8-CUZN37 F29 7
157 160 U-DISK 16
160 162 COVER 2
571 164 GEAR PUMP 630 E COMPL. 1
661 165 PUMP SUPPORT 630-MACH. 1
662 166 TAPER PIN 16X132-ST460TS 2
en HTGD 693 000 V0140 A

397
Fig.9 Blade carrier
398 HTGD 693 000 V0140 A en

Catalogue

Pos
7 168 NUT M64 124
48 171 GUIDE PIN DIA 105/155 1
51 172 SHIM D 64/13X0,15 14
52 173 COUNTERSINK DISK D71X23 2
75 175 SHIM D 64/13X0,2 14
96 176 LP BLADE CARRIER UH-MACH. 1
97 177 LP BLADE CARRIER LH-MACH. 1
162 178 GUIDE BOLT M64 X1900 2
163 179 TAPER PIN 36X375-ST460TS 4
en HTGD 693 000 V0140 A 399

Fig.10 Temperature- and jacking oil measurement
400 HTGD 693 000 V0140 A en

Catalogue

Pos
200 182 2-WAY CURRENT REGUL.VALVE 1
201 183 PLATE 1
202 184 OIL TEST VALVE G 1/2" A 1
203 185 PRES.MEAS.&JACK.OIL PIPES 1
204 186 THERMOCOUPLE TYPE N 1
205 187 VENTILATION PROTECTION 1
207 188 DOUBLE THERMOCOUPLE COMPL 2
208 189 BRG.TEMP.MEAS./INSTRUMENT 1
209 190 KNUCKLE MACHINED 2
210 191 HUB 1
211 192 BOLT 2
213 194 RE-RG 110X4 SP ST 4
en HTGD 693 000 V0140 A

401
Fig.11 Rotor measurement
402 HTGD 693 000 V0140 A en

Catalogue

Qty
Pos
654 197 BAR COMPL. 5/8-18UNF 1
656 199 P PIN 6X20 ST/BL 4
657 200 SUPPORT MACHINED 2
en HTGD 693 000 V0140 A

403
1.9 MAA10/MAC10 - High- Low Pressure Turbine Rotor -

HTGD800205V0004
Fig.1 HP/LP-Rotor
404 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd MDG100K/1-NE33AA

Qty
Pos
999 IL ROTOR READY FOR ASSEMBLY
1
2 1 GEAR WHEEL
1
16 2 TURBINE PINION Z = 31
1
19 3 FINAL DISC
1
20 4 HEX-S SCR M20X60 8.8/SW
4
24 5 KEY COMPL.
1
41 6 BALANCE PIN M24 X 70
5
45 7 BALANCE PIN M36 X 101
5
51 8 BALANC.SEGMENT 27.3X15X18
5
52 9 BALANC.SEGMENT 27.3X15X30
5
151 10 SEALING STRIP RD 5P
27
18
30
192 13 CALKING WIRE 2,8*2,0
239
205 14 COUPL.BOLT.M42-TK X 277
12
206 15 EXPANSION SLEEVE DIA 55.15
12
207 16 COUNTERSUNK NUT M42
12
208 17 LOCKING RING
24
209 18 COUNTERSUNK NUT M42 SPECIAL
12
en HTGD 693 000 V0140 A

405
1.10 MAC10 - Foundation Bolt - HTGD800035V0012
Fig.1 Foundation bolt
406 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd EGU/EH M80

Qty
Pos
999 FOUND.BOLT EGU/EH M80 CPL
1
2 1 FOUNDATION BOLT M80

1
4 2 SUPPORT DISC 170X90X40
1
5 3 SPECIAL NUT M80X70
1
6 4 PROTECTIVE COVER COMPLETE
1
7 5 HEX HD SCR M20X25 8.8/ZN
1
14 6 H-S-SCR-FDP M10X80 45H/ZN
3
15 7 ADJUSTING BOLT M16
1
16 8 STANDARD COMPRESSION SPRING
1
18 9 INNERRING MACHINED M180X4
1
19 10 NUT MACHINED M180X4
1
20 11 SUPPORT RING D280X19
1
en HTGD 693 000 V0140 A

407
1.11 MAC10 - Foundation Bolt - HTGD800035V0013
408 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd EGU/DH M80

Qty
Pos
999 FOUND.BOLT EGU/DH M80 COMPLETE
1

1
4 2 SPACER SLEEVE 160X112X110
1
1
1
1
1
9 7 HEX-S SCR M12-TX20 ST-GA
2
3
1
1
1
1
1
en HTGD 693 000 V0140 A

409
1.12 MAC31 - Butterfly-Type Valve - HTGD800007V0004
Fig.1 Steam trap
410 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Adams Armaturen NDK 350 left

Qty
Pos
999 NDK-VALVE, COMPLETE
1
991 1 STEAM TRAP

1
100 2 BODY COMPLETE, ST 1.0425
1
104 3 COVER, ST 1.0425
1
108 4 SCREW PLUG, ST/DIN 910
1
109 5 EYEBOLT, ST C 15
2
110 6 HEXAGON HEAD BOLT, 8.8/DIN 933
24
111 7 LOCKING PLATE, ST/DIN 93
24
112 8 GASKET, PT 2500 AF
1
120 9 TRAP, COMPLETE
1
121 10 TRAP BODY, ST 1.0425
1
122 11 TRAP BODY, ST 1.0425
1
123 12 FINE STRAINER, ST 1.7380
1
124 13 COMMISSIONING STRAINER, ST 1.7380
1
126 14 SOCKET HEAD SCREW, 8.8/DIN 912
4
127 15 SCREW PLUG, ST/DIN 910
4
en HTGD 693 000 V0140 A

411
Fig.2 Intermediate pipe
412 HTGD 693 000 V0140 A en

Catalogue

Pos
992 16 INTERMEDIATE PIPE 1
200 17 INTERMEDIATE PIPE, ST 1.0425 1
202 18 WELDING NECK FLANGE, ST 22.8 1
203 19 HEXAGON HEAD BOLT, 8.8/DIN 931 48
204 20 NUT, KL.8/DIN 934 32
205 21 GASKET, ST/GRAFIT 4
en HTGD 693 000 V0140 A 413

Fig.3 Hinged support
414 HTGD 693 000 V0140 A en

Catalogue

Pos
993 23 HINGED SUPPORT 4
301 24 SUPPORT, R-ST 37-2 4
304 25 PIPE, ST 37 4
305 26 BOLT, ST 50-2K 8
306 27 PIVOTING HEAD WITH LEFT-HAND THREAD, ST 4
307 28 PIVOTING HEAD WITH LEFT-HAND THREAD, ST 4
308 29 NUT WITH RIGHT-HAND THREAD, ST 4
309 30 NUT WITH LEFT-HAND THREAD, ST 4
310 31 WASHER, ST/DIN 1440 16
311 32 CIRCLIP, ST/DIN 471 16
en HTGD 693 000 V0140 A 415

Fig.4 Actuator
416 HTGD 693 000 V0140 A en


Pos
994 33 ACTUATOR 2
401 34 BODY, FE 430B 1
402 35 PINION, C 45 1
403 36 SHAFT, 39NICRMO3 1
404 37 EXTERNAL HEAD, FE 430B 1
405 38 PISTON, FE 430B 1
406 39 CYLINDER, ST 52.0 1
407 40 STAY BOLT, 39NICRMO3 8
408 41 BUSHING, BSZN5 1
410 43 SPRING COVER, FE 430B 1
411 44 COVER, FE 430B 1
412 45 COVER, FE 430B 1
414 47 O-RING, VITON 1
415 48 O-RING, NBR 1
416 49 COVER GASKET, NBR 1
418 51 HEXAGON HEAD BOLT, 8.8 12
419 52 SOCKET HEAD SCREW, 8.8 4
en HTGD 693 000 V0140 A 417

Fig.4 Actuator
418 HTGD 693 000 V0140 A en

Catalogue

Pos
421 54 NUT, 6 S 4
422 55 STAY BOLT, ST 35.1 6
423 56 SCREW, FE 430B 6
424 57 SPRING BODY, ST 35.1 1
425 58 DISC, FE 430B 1
426 59 FLANGE, FE 430B 1
428 61 FLANGE, FE 430B 1
429 62 SHAFT, C 45 1
430 63 POS. STOP BOLT, C 45 1
440 64 BLOCK NUT, FE 430B 1
442 66 RACK, C 45 1
444 68 BELLEVILLE SPRING SET, 50CRV4 1
445 69 POS. STOP BOLT, C 45 1
446 70 BLOCK NUT, 8.8 1
448 72 PISTON GUIDANCE, CARBOGRAFIT 1
449 73 DISC, FE 430B 1
en HTGD 693 000 V0140 A 419

Fig.5 Pilot control for control valve
420 HTGD 693 000 V0140 A en

Catalogue

Pos
995 76 PILOT CONTROL FOR CONTROL VALVE 1
501 77 BODY, GGG 40 1
502 78 BODY COVER, ST 37 1
503 79 COVER, R ST 37-2 1
504 80 VALVE SEAT, ST 1.1181 1
505 81 VALVE PLATE, ST 1.7225 1
508 84 PROPORTIONAL CONTROL VALVE 1
509 85 PROTECTION, ST 37 1
510 86 DISC ORIFICE 1
511 87 DISC ORIFICE 1
522 91 CHECK VALVE, ST 1
523 92 THREADED STEM, ST 2
526 95 SCREW PLUG, ST 1
527 96 EYEBOLT, ST C 15 1
532 101 SPRING WASHER, HRC 44 4
535 102 COMPRESSION SPRING, ST 1.1200 1
580 103 POWER AMPLIFIER 1
en HTGD 693 000 V0140 A

421
Fig.6 Pilot control for stop valve
422 HTGD 693 000 V0140 A en

Catalogue

Pos
996 104 PILOT CONTROL FOR STOP VALVE 1
601 105 BODY, GGG 40 1
602 106 BODY COVER, ST 37 1
603 107 COVER, R ST 37-2 1
604 108 VALVE SEAT, ST 1.1181 1
605 109 VALVE PLATE, ST 1.7225 1
608 112 DIRECTIONAL CONTROL VALVE 1
609 113 PROTECTION, ST 37 1
622 116 CHECK VALVE, ST 1
626 118 SCREW PLUG, ST 1
627 119 EYEBOLT, ST C 15 1
632 124 SPRING WASHER, HRC 44 4
635 125 COMPRESSION SPRING, ST 1.1200 1
en HTGD 693 000 V0140 A 423

Fig.7 Terminal box
424 HTGD 693 000 V0140 A en

Catalogue

Pos
997 126 TERMINAL BOX 2
701 127 BASE PLATE, ST W 23 1
702 128 COVER, ST W 23 1
703 129 DISC, ST 1.0038 1
704 130 COUPLING, ALU 1
705 131 TRIP CAM, ST 1.0038 1
706 132 PIPE, ST 1.0038 4
707 133 SOCKET HEAD SCREW, 8.8/DIN 912 4
708 134 SOCKET HEAD SCREW, 8.8/DIN 912 4
710 136 GRUB SCREW, 45H/DIN 913 1
711 137 GRUB SCREW, 45H/DIN 913 1
712 138 FLAT HEAD SCREW, DIN 85A 12
713 139 WASHER, DIN 125A 12
714 140 TYPE PLATE, ST 1.4301 1
715 141 DIRECTION ARROW, ST 1.4301 1
716 142 PLATE "OPEN", ST 1.4301 1
717 143 PLATE "SHUT", ST 1.4301 1
718 144 RIVET, AZ/DIN 7337 6
720 145 POSITION TRANSMITTER 1
721 146 PLUG 1
722 147 CLAMP, ST 4
725 148 PROXIMITY SENSOR 2
726 149 NUT 4
727 150 PLUG 2
en HTGD 693 000 V0140 A 425

Fig.8 Tight-shut-off valve
426 HTGD 693 000 V0140 A en

Catalogue

Pos
998 151 TIGHT-SHUT-OFF VALVE 2
1000 152 VALVE BODY, GS-C25N 1
1180 153 CLOSE STOP, P 265 GH 1
1610 154 SEAL RING, GRAPHIT 1
1660 155 SEALING, INCONEL 625 1
1890 156 THRUST COLLAR, 13 CRMO 4-5 1
1910 157 RETAINING RING, P 265 GH 1
1920 158 GRUB SCREW, A 4-70 30
1940 159 PARALLEL PIN, A 4-70 3
1950 160 TAB WASHER, X6CRNIMOTI17122 3
1960 161 SCREW, A 4-70 3
2000 162 DISC, GS-C25N (SVB COATED) 1
2100 163 SPLINE BUSH, X2CRNIMON22 5 3 1
2110 164 GUIDE BUSH, X2CRNIMON22 5 3 1
3000 165 DRIVE SHAFT, X20CRNI 17 2 1
3110 166 BEARING RING, GGG-NICR20 2 1
3120 167 BEARING, GGG-NICR20 2 1
3130 168 BEARING SEAL, GRAPHIT 1
3210 169 BEARING RING, GGG-NICR20 2 1
3220 170 BEARING, GGG-NICR20 2 1
3230 171 BEARING SEAL, GRAPHIT 1
3300 172 SPACER, X5CRNI18 10 1
3320 173 SPACER, GRAPHIT 1
en HTGD 693 000 V0140 A 427

Fig.8 Tight-shut-off valve
428 HTGD 693 000 V0140 A en

Catalogue

Qty
Pos
3340 174 SPACER, GRAPHIT
1
3410 175 CAP, GS-C25N
1
3420 176 GASKET, GRAPHIT
1
3430 177 HEXAGON HEAD BOLT, 5.6
4
4100 178 PACKRING, GRAPHIT
1
4150 179 STUD, C 3
4
4210 180 GLAND BUSHING, X5CRNI18 10
1
4220 181 GLAND FLANGE, X5CRNI18 10
1
4250 182 BELLEVILLE SPRING SET
4
4260 183 SPRING HOLDER, X6CRNIMOTI17122
4
4270 184 STOPPER, X5CRNI18 10
4
4300 185 OFF-SHUT-PLATE, X5CRNI18 10
4
4310 186 LOCK WASHER, SPRING STEEL
4
6010 187 CAP, C 22.8
1
6020 188 SLIT RING, GGG-NICR20 2
1
6030 189 BEARING, GGG-NICR20 2
1
6050 190 BRACKET, GGG-40
1
6100 191 PARALLEL PIN, 9SMNPB28K
2
6110 192 HEXAGON HEAD SCREW, 5.6
4
6120 193 SOCKET HEAD SCREW, 5.8
4
6801 194 SCREW PLUG, 5.8
2
6802 195 SEALING , CU
2
6910 196 ARROW, X5CRNI18 10
1
6920 197 TAG "PRESSURE DIR.", X5CRNI18 10
1
8010 198 TYPE PLATE, X5CRNI18 10
1
en HTGD 693 000 V0140 A
429
1.13 MAD20 - Foundation Bolt - HTGD800035V0010
430 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd EGU/EH M80

Qty
Pos
999 FOUND.ANCHOR EGU/EH M80
8

1
1
1
1
1
3
1
1
1
1
1
en HTGD 693 000 V0140 A

431
1.14 MAD20 - Thrust Bearing Pedestal - HTGD800099V0014
Fig.1 Base plate
432 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd VLB 355 Oil side left

Qty
Pos
999 VLB-BEARING BLOCK COMPLETE
1
24 1 SHIM
4
25 2 CLAW
4
8
8
32 5 BASE PLATE
1
33 6 LOCKING PLATE
4
34 7 CASING SLIDING PIECE
4
8
36 9 KEY
2
37 10 SHIM SET
4
38 11 SLIDING PLATE
4
39 12 CS SCREW,CR M6X12 ST S
12
4
14
42 15 LOCK WASHER
2
en HTGD 693 000 V0140 A

433
91
84,85
12 82
B 16
15
21
14 22
20
13
B
31
77
76
74
2
17
44
75
55 43
77
A
56 41
A
501
ALNA0302_
A1873
Fig.2 Bearing pedestal, lower half

434 HTGD 693 000 V0140 A
en
Catalogue

Pos
2 16 BEARING PEDESTAL LOWER HALF LAGER 355 1
12 17 SUPPORT KEY MACHINED 1
13 18 SUPPORT KEY MACHINED 1
14 19 HEXAGON SOCKET SCREW M42-TX80 ST-GA 8
15 20 WASHER:A 10.5/20 SS 2
16 21 HEXAGON SOCKET SCREW M10-TX25 ST-GA 2
17 22 VERTICAL SHIMSET 2
20 23 HEXAGON SOCKET SCREW M12-TX65/ ST-GA 4
21 24 SPHERIC.SUPPORT 125 DEVA 2
31 26 SHIM SET 6
43 28 BLIND FLANGE 1
44 29 GASKET THICKNESS: 2MM 1
55 30 LO-WA 31/55X80 ST07/12 2
74 32 EXP.STUD BOLT M56-TKX250 4
75 33 SLEEVE MACHINED 4
76 34 DISTANCE WASHER 4
77 35 HEXAGON-NUT-0.8D M56 8/ZN 8
82 36 SHAFT POSITION MONITOR 1
85 38 L-WAS,1H 13/25X25 ST/BL 2
91 39 PIN S-SW 6X20 STS 2
501 40 ABSOLUTE EXPANSION MEASUREMENT 1
en HTGD 693 000 V0140 A 435

11
152
23
7 154
A
155
153
150
11
78
18 23
79
78 151
155
154
10
11
ALNA0307_
A3180
Fig.3 Bearing pedestal, lower half
436 HTGD 693 000 V0140 A

en
Catalogue

Pos
7 41 JOURN-THRUST BEARING DIA 355 1
10 42 LO-WA 10.5/20X30 ST07/12 12
18 44 LOCK WASH JAC 10 ST/BL 12
23 45 PROFILE 2X8-CUZN37 F29 14
46 47 P PIN 12X25 ST/BL 2
47 48 PLUG 1
48 49 FLANGE 1
49 50 SEAL 1MM THICK 1
50 51 ORIFICE =31MM 1
51 52 HEXAGON HEAD SCREW M16X35 8.8/HDG 2
52 53 HEXAGON SOCKET SCREW M8X70/ 8.8/A2G 2
78 55 COUPLING COVER CPL. 1
150 57 OIL SCRAPER UPPER HALF 1
151 58 OIL SCRAPER LOWER HALF 1
152 59 OIL SCRAPER UPPER HALF 1
153 60 OIL SCRAPER LOWER HALF 1
154 61 HEX-S-PLUG G3/8A ST/ZN 2
155 62 GASKET 21.9/18.2X1.5 2
en HTGD 693 000 V0140 A 437

WP4140
86
503
8
505
131
132
133
504
502
70
506
ALNA0407_
A2452_
Fig.4 Bearing pedestal, upper half
438 HTGD 693 000 V0140 A

en
Catalogue

Qty
Pos
1 63 BEARING PEDESTAL UPPER HALF 1
4 65 HEXAGON HEAD CAP NUT M42 12
5 66 CAP 80X69X1 12
6 67 TAPER PIN 16X160 COMPL. 2
8 68 ROTOR TURNING GEAR 1
70 69 COUPLING CPL. WITH CONNECTOR 1
86 70 INSTALLATION SPEED SENSOR 1
131 71 COVER 3
132 72 GASKET THICKNESS: 1MM 3
502 74 PHASE ANGLE MEASUREMENT 1
503 75 SHAFT VIBRATION MEASUREMENT 2
504 76 SENSOR SUPPORT 1
505 77 SPACER SLEEVE 3
506 78 SENSOR SUPPORT 1
en HTGD 693 000 V0140 A

439
128 129 118 109 8
113 109
110
122
101
212
205
105
217
102 121
107
117
106
114
127 129
ALFA0306_
A2451_
Fig.5 Oil lines
440 HTGD 693 000 V0140 A

en
Catalogue

Pos
8 79 ROTOR TURNING GEAR 1
101 80 2-WAY CURRENT REGUL.VALVE 1
102 81 HEXAGON SOCKET SCREW M8X45/ 8.8/A2G 4
105 82 HEXAGON SOCKET SCREW M8X50/8.8/A2G 4
106 83 ELBOW W 12 ST 1
107 84 PLATE 1
110 86 PIPE JOINT G 16 ST 1
113 87 ELBOW W 16 ST 1
117 89 PIPE 12 -
118 90 PIPE 16 -
121 91 CLAMP 12-PP 1
122 92 CLAMP 16-PP 2
129 95 LO-WA 6.4/15X15 ST07/12 6
205 96 UNION GE 12XG3/8A ST 1
212 97 HEXAGON HEAD S PLUG G 3/8A ST ZN 2
217 98 ANGULAR PIPE UNION EW12ST 1
en HTGD 693 000 V0140 A 441

119 68,64 119
68,64
66,63
220,64
66,63 61
66,63
220,64 68,64
120
68,64
68,64 67,63
66,63
66,63 66,63
59
60
66,63 67,63
66,63
57 11
62
58
ALNA0306_
Fig.6 Thermocouples
442 HTGD 693 000 V0140 A

en
Catalogue

Qty
Pos
57 100 FLANGE 1
58 101 GASKET THICKNESS: 1,5 MM 1
59 102 TERMINAL BOX COMPL. 1
60 103 TERMINAL BOX COMPL. 1
62 105 CABLE GLAND 6
66 108 DOUBLE CLAMP 7
67 109 CLAMP 3
68 110 PIPE CLAMP D10/15 6
220 113 PIPE CLAMP D20/15 4
en HTGD 693 000 V0140 A

443
1.15 MAD21 - Combined Thrust and Journal Bearing -

HTGD800002V0012
Fig.1 Thrust and journal bearing
444 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power 355

Qty
Pos
999 JOURN-THRUST BEARING 355
1
1 1 BEARING BODY LH MACHINED

1
2 2 BEARING BODY UH MACHINED
1
3 3 FITTED PLATE
1
4 4 FITTED PLATE
1
5 5 FITTED PLATE
2
6 6 FITTED PLATE
2
7 7 PROFILE 2X8- CUZN37 F29
7
8 8 HEXAGON HEAD SCREW M24X150/60 ST
4
9 9 TAPER PIN 16X160 COMPL.
2
10 10 L.WASHER 1L-25X50 ST/A4G
4
11 11 HEXAGON-S SCREW M16X30 8.8/SW
12
12 12 PIN S-SW 10X25 STFD SHW
12
12 13 PIN S-SW 10X25 STFD SHW
40
15 14 SHELL INSERT,LH MACHINED
1
16 15 SHELL INSERT,UH MACHINED
1
17 16 HEXAGON-S SCREW M16X45 8.8/SW
4
18 17 PIN P 12X30 ST/BK
2
19 18 PIN P 30X60 ST/BK
1
20 19 HP-PLUG M12X28/26.5
1
21 20 THRUST PAD MACHINED
8
22 21 THRUST PAD MACHINED
8
en HTGD 693 000 V0140 A
445
Fig.1 Thrust and journal bearing
446 HTGD 693 000 V0140 A en


Pos
23 22 THRUST PAD MACHINED 2
24 23 THRUST PAD MACHINED 2
32 24 HALVE RING-UPPER PART 1
33 25 HALVE RING-LOWER PART 1
40 26 RING TWO-PIECE 1
41 27 SHIM SET 1
42 28 LOCKING PLATE 4
43 29 PIN 1
44 30 SHIM SET 8
46 31 SHIM SET 1
47 32 SHIM SET 2
48 33 THREADED PIN 2
50 34 P-H-SCREW M8X20 4.8/ZN 28
51 35 CS-SCR,SL M5X16 4.8/ZN 4
55 36 ORIFICE DA=11 4
56 37 CHECK VALVE RC 2 1
en HTGD 693 000 V0140 A 447

1.16 MAD51 - Pocket-Type Journal Bearing - HTGD800093V0013
Fig.1 Pocket bearing
448 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd 315 R1T Not insulated

Qty
Pos
999 POCKET BEARING 315
1
11 1 BEARING SHELL LH
1
15 2 BEARING SHELL UH
1
30 3 FITTED PLATE 130X29.5X90
1
2
2
1
41 7 SHIM 0.20 MM
8
42 8 SHIM 0.15 MM
8
43 9 SHIM 0.20 MM
16
44 10 SHIM 0.15 MM
16
46 11 PIN P 30X70 ST/BK
1
49 12 BUSHING
1
50 13 DOWEL PIN 25X50
2
52 14 HP-PLUG M12X28/26.5
1
54 15 CHECK VALVE RC 2
1
56 16 HEXAGON SOCKET SCREW M16X80/ 8.8/SW
4
57 17 HEXAGON SOCKET SCREW M12X25 8.8/SW
8
60 18 HEXAGON SOCKET SCREW M10X40 45H/A3G
2
67 19 PIN P 8X30 ST/BK
12
en HTGD 693 000 V0140 A
449
1.17 MAV21AP011 - Gear Pump - HTGD800047V0011
Fig.1 Gear pump
450 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd 630 ELR

Qty
Pos
999 GEAR PUMP 630 E COMPLETE
1
1 1 PUMP CASING
1
2 2 BEARING FLANGE-NS
1
4 3 TOOTH PISTON
1
5 4 TOOTH PISTON
1
6 5 RADIAL BEARING
4
7 6 FORGED-ON SHAFT COLLAR
1
9 7 SCREW
1
10 8 BOLT 33
4
11 9 LOCKING PLATE
1
12 10 WEDGE
1
13 11 HEXAGON NUT 0.8D M8 8/ZN
4
14 12 HEXAGON HD-S-PLUG G1/4A ST/ZN
4
4
8
17 15 LOCK WASHER 16 ST/BK
8
18 16 CO SPR WASHER 21/40 ST/BK
8
19 17 PIN T-GA 8X60 ST50K/BK
4
20 18 BAL-PLUG G3/4ZX10 ST
4
21 19 LIFT EYEBOLT M10 ST/ZN
2
22 20 U-SHB:A 28/50 ST/BK
4
24 21 BEARING FLANGE-AS
1
25 22 PIPELINE
1
27 23 PIPE CLAMP
1
28 24 HEXAGON HEAD SCR M10X20 8.8/ZN
2
29 25 LOCK WASHER 2L 10.5/20X40 ST/BK
1
30 26 PUMP GEAR WHEEL Z=48
1
en HTGD 693 000 V0140 A

451
1.18 MAX43 - Trip Unit - HTGD800032V0003A
Fig.1 Trip unit
452 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd TBOS90

Qty
Pos
999 TRIP BLOCK UNIT COMPLETE
1
1 1 PLATE
1
3 2 PISTON
3
4 3 COVER
3
3
6 5 PROTECTION PLATE
1
1
10 7 2/2-WAY SEAT VALVE MAX43AA111 MAX43AA11
3
11 8 3-WAY COMPACT BALL COCK
3
12 9 CHECK VALVE RC 2
6
13 10 HEXAGON HEAD S PLUG G3/8A ST/ZN
5
19 11 SCREW PLUG R1/2"
6
23
4
22 14 HEXAGON SOCKET SCREW M6X35/ 8.8/SW
15
12
25 16 SPRING LOCK WASHER 8 ST/BK
12
26 17 LIFT EYEBOLT M10 ST/ZN
2
29 18 ROD SEAL
3
30 19 WIPING SEAL
3
31 20 ROUND.SEAL RI.50.16X5.34 G80
3
4
2
34 23 SPRING LOCK WASHER 6 ST/BK
6
en HTGD 693 000 V0140 A

453
1.19 MAX44 - Sequence Valve - HTGD800031V0005B
Fig.1 Sequence valve
454 HTGD 693 000 V0140 A en

Catalogue
Manufacturer Type
Alstom Power Ltd TBVS90

Qty
Pos
999 2 OUT OF 3 TRIPBLOCK
1
1 1 TRIP BLOCK
1
1
4 3 VALVE SPOOL
1
5 4 COVER
1
6 5 COVER
1
7 6 PISTON
1
8 7 HOUSING
1
9 8 COVER
1
10 9 DISC
1
11 10 PLATE
1
12 11 ORIFICE G1/2"/D1,2
1
13 12 ORIFICE G1/2"/D1,2
1
14 13 ORIFICE G3/8"/D3
1
15 14 ORIFICE G3/8"/D1,7
1
16 15 ORIFICE G3/8"/D1,7
1
18 16 CHECK VALVE, RVC-16-1/ESH-25
1
20 17 GASKET
1
21 18 GASKET
1
22 19 GASKET
1
24 20 PROTECTION
1
25 21 PRESS. SPRING F.VALVE SP.
1
26 22 PRESS. SPRING F.DISH
1
27 23 PRESS. SPRING
1
31 24 CHECK VALVE RC3
2
34 25 RD.SEAL RI.50.16X5.34 G80
3
34 26 RD.SEAL RI.50.16X5.34 G80
1
35 27 RD.SEAL RI.110,5X5,34 G80
1
36 28 RD.SEAL.RI.10,78X2,62 G80
2
37 29 RD.SEAL RI.28.17X3.53 G80
1
en HTGD 693 000 V0140 A

455
Fig.1 Sequence valve
456 HTGD 693 000 V0140 A en


Pos
30 30 IND. PROXIMITY SWITCH 1
38 31 RD.SEAL RI.21.82X3.53 G80 2
39 32 BUSHING 1
42 33 SET SCREW,SL,FP M16X22 1
45 37 HEX-S-SCP M6X8 45H/SW 1
46 38 HEX HD SCREW M16X200/8.8/ZN 4
47 39 HEX-S SCREW M16X100/ 8.8/SW 4
48 40 HEX-S SCREW M12X50/ 8.8/A3G 4
49 41 HEX-S SCREW M12X40/ 8.8/A3G 4
50 42 HEX-S SCREW M8X45/ 8.8/A2G 4
50 43 HEX-S SCREW M8X45/ 8.8/A2G 2
51 44 HEX-S SCREW M6X20 8.8/A2G 4
52 45 HEX-S SCREW M6X16 8.8/A2G 2
54 46 WASHER 6.4/11 ST/ZN 4
55 47 SPRING LOCK WASHER 6 ST/BK 4
56 52 SPR-LOCKWASHER 12 ST/BK 8
57 53 LOCKWASHER,1L 13/25X25 ST/ZN 1
60 54 SCREW PLUG G3/4A 1
en HTGD 693 000 V0140 A 457

Blank Page
HTGD800000V0000
458 HTGD 693 000 V0140 A en

MA - Test Certificates/Datasheets
en HTGD 693 000 V0140 A 459

Revision History
total :
- - (424)
460 HTGD 693 000 V0140 A en

Contents
1 Test Certificates
List...............................................................................
............................ 467
1.1 1BSE001367_B_ANCHORAGE OF
TURBINE ..................................................... 467
1.2 1BSE001373_A_LOCATION OF
INSTRUMENTS ................................................ 469
1.3 1BSE001374_-_SHIPMENT
INFORMATION........................................................ 471
1.4 1BSE001375_-_TURBINE
INSULATION .............................................................. 473
1.5 1BSE001376_-_GROUNDING CONCEPT
INFORM. ........................................... 475
1.6 1BSE001377_-_LONGITUDINAL
SECTION ......................................................... 477
1.7 1BSE001405_B_P&ID STEAM
TURBINE............................................................. 479
1.8 1BSE001637_-_CLEARANCE TABEL(HD) - ASSEMBLY CLEARANCES -
RADIALAXIAL........................................................................
................................ 485
1.9 1BSE001713_-_HYDR. AND LUBE OIL
UNIT ...................................................... 501
1.10 1BSE001715_A_P&ID LUBE OIL
PURIFIER ........................................................ 503
1.11 1BSE001848_-_EXPANS. SLEEVE
COUPLING .................................................. 505
1.12 1BSE001957_-_ADJUSTMENT DIAGRAM
CV1................................................... 507
1.13 1BSE001958_-_ADJUSTMENT DIAGRAM
NDK .................................................. 509
1.14 1BSE501022_B_LEGEND FOR P&ID
ST ............................................................. 511
1.15 1BSE501152_-_DESCRIPTON OF ST
SYSTEMS ............................................... 525
1.16 1BSE501156_A_I_O LIST
ST ...............................................................................
545
1.17 1BSE501157_B_START & OPER.
INSTRUCTION .............................................. 553
1.18 1BSE501163_-_DESCR. OF ST
CONTROLLER.................................................. 595
1.19 1BSE501424_A_LEGEND P&ID
PURIFIER ......................................................... 609
1.20 1BSE501638_-_BALANCING WEIGHT DISTRIBUTION(MDG100K) - MN-
ROTOR .............................................................................
..................................... 613
1.21 HTCT692082V0001- - General Bolted Connections, Tightening Torques
and Prestressing
Forces ............................................................................
............ 615
1.22 HTGD499340_-_CLEARANCE CHECH OF HOLD-DOWN BAR(TBS) - TC-
BEARING
PEDESTAL ..........................................................................
................. 621
1.23 HTGD499343_A_CLEARANCES OF OIL SHIELDS(TBS-IBS-DBS-NBS-
EBS) - TC-BEARING
PEDESTAL .........................................................................
623
en HTGD 693 000 V0140 A

461
WP4140
1.24 HTGD499345_-_CLEARANCE SPEED SENSOR(TBS1) - TC-BEARING
PEDESTAL ..........................................................................
.................................. 625
1.25 HTGD630064_A_ITH110
HYDR.STRETCH.BOLTS(1) ........................................ 627
1.26 HTGD630122_C_MA-LUBE OIL
SYSTEM ........................................................... 635
1.27 HTGD630136_A_MA-VALVE STEM
PACKING .................................................... 657
1.28 HTGD630147_B_TIGHTENING
TORQUE............................................................ 663
1.29 HTGD630178_B_FLUSHING PROCEDURE
FAST.............................................. 667
1.30 HTGD667183_A_ADJUSTMENT OF TURBINE INSTRUMENT(VLA) - TC-
BEARING
PEDESTAL...........................................................................
................ 697
1.31 HTGD667205_-_MAIN STROKE CHECK VALVE BLOCK COMPLETE(FD-
SSVM250 - CV1) - STOP
VALVE.......................................................................... 699
1.32 HTGD667206_-_MAIN STROKE CHECK VALVE BLOCK
COMPLETE(STVM200 - CV1) - CONTROL
VALVE ............................................. 701
1.33 HTGD667229_-_CHECK OF CORRECT VALVE
ARRANGEMENT(MDG100K) - TURBINE
COMPLETE ........................................ 703
1.34 HTGD667230_-_IP-STEAM DUCT BOLT PRESTRESS(MDG100K) -
STEAM
DUCT ..............................................................................
......................... 705
1.35 HTGD667231_-_SWING ARM SUPPORT ADJUSTMENT(MDG100K) -
SPRING LOADED
SUPPORT............................................................................
... 707
1.36 HTGD667232_-_SET VALUES FOR STOP VALVE ASSEMBLY-
REASSEMBLY(CV1) - SET
VALUES.................................................................... 709
1.37 HTGD667233_-_SET VALUES FOR CONTROL VALVE ASSEMBLY-
REASSEMBLY(CV1) - SET
VALUES.................................................................... 711
1.38 HTGD667235_-_BOLT PRESTRESS IP-OUTER CASING(MDG100K) -
BOLT
PRESTRESS..........................................................................
..................... 713
1.39 HTGD667236_-_BOLT PRESTRESS LP-OUTER CASING(NE41A) - BOLT
PRESTRESS .........................................................................
................................ 715
1.40 HTGD667237_-_BOLT PRESTRESS IP-INNER CASING(MDG100K) -
BOLT
PRESTRESS..........................................................................
..................... 717
1.41 HTGD667238_-_BOLT PRESTRESS LP-BLADE CARRIER(NE41A) -
BOLT
PRESTRESS..........................................................................
..................... 719
1.42 HTGD667239_-_BOLT PRESTRESS VERTICAL FLANGE(MDG100K) -
BOLT
PRESTRESS..........................................................................
..................... 721
462 HTGD 693 000 V0140 A

en
1.43 HTGD667240_-_LEVELLING OF THE IP-LP OUTER CASING(MDG100K-

NE41A) - CASING
LEVELLING..........................................................................
... 723
1.44 HTGD667241_-_DIMENSIONAL CHECK OF INTERMEDIATE
PIPE(MDG100K) - INTERMEDIATE
PIPE ............................................................ 725
1.45 HTGD667244_-_LP-GLAND SEAL RADIAL AND AXIAL
CLEARANCES(NE41A) - GLAND
SEAL ............................................................... 727
1.46 HTGD667246_A_POSITION CHECK OF INNER PARTS IN IP-OUTER
CASING(MDG100K) - POSITION
CHECK ............................................................ 729
1.47 HTGD667247_-_IP-INNER CASING FIXING ELEMENTS(MDG100K) -
ADJUSTING
ELEMENT............................................................................
............. 731
1.48 HTGD667248_-_IP-INNER CASING FIXING ELEMENTS(MDG100K) -
ADJUSTING
ELEMENT............................................................................
............. 733
1.49 HTGD667249_-_IP-INNER CASING FIXING ELEMENT
HORIZONTAL(MDG100K) - ADJUSTING
ELEMENT ........................................... 735
1.50 HTGD667250_A_IP-INNER CASING FIXING ELEMENT
HORIZONTAL(MDG100K) - ADJUSTING
ELEMENT ........................................... 737
1.51 HTGD667251_-_LP-BLADE CARRIER FIXING HORIZONTAL-
VERTICAL(NE41A) - ADJUSTING
ELEMENT ...................................................... 739
1.52 HTGD667252_-_POSITION CHECK OF IP-STEAM DUCT(MDG100K) -
STEAM
DUCT...............................................................................
......................... 741
1.53 HTGD667254_-_IP-TURBINE COMPLETE CHECK OF THE
CONNECTION DIMENSIONS(MDG100K) - CONNECTION DIMENSION ........... 743
1.54 HTGD667255_-_CHECK ROTOR POSITION TO INNER
CASING(MDG100K) - ROTOR_INNER
CASING.................................................. 745
1.55 HTGD667256_-_CHECK ROTOR POSITION TO OUTER
CASING(MDG100K) - ROTOR_OUTER
CASING ................................................ 747
1.56 HTGD667257_-_POSSIBLE DISPLACEMENT AXIAL ROTOR TO
CASING(MDG100K-NE41A) -
ROTOR_CASING ................................................. 749
1.57 HTGD667259_-_PRE-STRESSED FOUNDATION BOLT(GENERAL - MA)
- FOUNDATION
BOLTS .............................................................................
........... 751
1.58 HTGD667260_-_POSITION CHECK(NE41A) - BLADE CARRIER
POSITION - RELATIVE TO
ROTOR ..................................................................... 753
1.59 HTGD667261_-_LP-TURBINE FOUNDATION KEY FIXING(NE41A) - LP-
TURBINE
FOUNDATI0N ........................................................................
............... 755
en HTGD 693 000 V0140 A

463
WP4140
1.60 HTGD667262_-_OUTER CASING CHECK THE ADJUSTING

CLEARANCES OF THE SUPPORT(NE41A) - LP-
SUPPORT .............................. 757
1.61 HTGD667263_-_BEARING CLEARANCE AND OIL POCKET CHECK(R1T
- D315) - TC-JOURNAL
BEARING........................................................................ 759
1.62 HTGD667264_-_ADJUSTING DIMENSIONS FOR DIFFERENTIAL
EXPANSION() - DIFFERENTIAL
EXPANSION..................................................... 761
1.63 HTGD667265_-_BACKLASH TEST OF MAIN OIL PUMP(MAV21) - LP-
BEARING
SECTION............................................................................
.................. 763
1.64 HTGD667266_-_LP-EXHAUST CONE(NE41A) - POSITION TEST -
ROTOR TO EXHAUST
CONE ..............................................................................
765
1.65 HTGD667267_-_CLEARANCE CHECK OF OIL SHIELD(NE41A) - LP-
BEARING
PEDESTAL...........................................................................
................ 767
1.66 HTGD667268_-_TURBINE FOUNDATION LEVELLING
POINTS(GENERAL - MA) - TC-
LEVELLING ........................................................ 769
1.67 HTGD667269_-_DISASSEMBLY AND ASSEMBLY OF
ROTORS(GENERAL - MA) - TC-SHAFT
LINE ..................................................... 771
1.68 HTGD667270_A_EXPANSION SLEEVE COUPLING FOR IP-LP(SHK 400)
- TC-EXPANSION
SLEEVE.............................................................................
...... 773
1.69 HTGD667271_-_DISPOSITION OF SLINGS(VLB) - TC-BEARING
PEDESTAL ..........................................................................
.................................. 775
1.70 HTGD667272_-_CLEARANCE CHECK BEARING PEDESTAL-BASE
PLATE(VLB) - TC-BEARING
PEDESTAL ............................................................. 777
1.71 HTGD667273_-_CHECK THE BEARING CLEARANCE THRUST AND
JOURNAL BEARING(VLB - �355) - TC-BEARING
PEDESTAL .......................... 779
1.72 HTGD667274_-_ROTOR POSITION IN BEARING PEDESTAL(VLB) - TC-
BEARING
PEDESTAL...........................................................................
................ 781
1.73 HTGD667275_-_AXIAL CLEARANCE MEASUREMENT OF BEARING
PEDESTAL-TURBINE(VLB) - TC-BEARING
PEDESTAL..................................... 783
1.74 HTGD667276_-_CLEARANCE MEASUREMENT HOLD-DOWN BAR
TURBINE-BEARING PEDESTAL(VLB) - TC-BEARING
PEDESTAL.................... 785
1.75 HTGD667277_-_CLEARANCE MEASUREMENT VERTICAL KEY
BEARING PEDESTAL-TURBINE(VLB) - TC-BEARING
PEDESTAL.................... 787
1.76 HTGD667459_-_ROTOR POSITION NE-BEARING PEDESTAL(NE ) -
NE-BEARING
PEDESTAL...........................................................................
.......... 789
464 HTGD 693 000 V0140 A

en
MA - Test
Certificates/Datasheets
1.77 HTGD672031_B_INSPECTION
PLANS................................................................ 791
1.78 HTGD672059_D_INSPECTION
REC.................................................................... 793
1.79 HTGD479232_A_() - HYDRAULIC
PRESTRESS ................................................. 797
1.80 HTGD479469_A_() - FUNCTIONAL
TEST............................................................ 799
1.81 HTGD479470_A_() - FUNCTIONAL
TEST............................................................ 801
1.82 HTGD691538D0401_-_Hand Lever Pressure Pump
Unit ..................................... 803
1.83 HTGD691538D0410_-_High Pressure Pump
Unit ................................................ 807
1.84 HTGD691538D0413- - High Pressure Hand Lever
Pump ..................................... 811
1.85 HTGD691538D0414- - High Pressure Pump
Unit ................................................. 815
1.86 HTGD691539V0001A - Flared Tube
Fitting........................................................... 819
1.87 HTGD691613V0002A - Vacuum Breaking
Valve .................................................. 835
1.88 HTGD691631V0002A - Globe
Valve ..................................................................... 861
en HTGD 693 000 V0140 A

465
-
466 HTGD 693 000 V0140 A en

1 TEST CERTIFICATES LIST
1.1 1BSE001367_B_ANCHORAGE OF TURBINE
1BSE001367_B_ANCHORAGE OF TURBINE
en HTGD 693 000 V0140 A 467

& WP4140
Blank Page
468 HTGD 693 000 V0140 A en

1.2 1BSE001373_A_LOCATION OF INSTRUMENTS

1BSE001373_A_LOCATION OF INSTRUMENTS
en HTGD 693 000 V0140 A 469

& WP4140
Blank Page
470 HTGD 693 000 V0140 A en

1.3 1BSE001374_-_SHIPMENT INFORMATION

1BSE001374_-_SHIPMENT INFORMATION
en HTGD 693 000 V0140 A 471

& WP4140
Blank Page
472 HTGD 693 000 V0140 A en

1.4 1BSE001375_-_TURBINE INSULATION

1BSE001375_-_TURBINE INSULATION
en HTGD 693 000 V0140 A 473

& WP4140
Blank Page
474 HTGD 693 000 V0140 A en

1.5 1BSE001376_-_GROUNDING CONCEPT INFORM.

1BSE001376_-_GROUNDING CONCEPT INFORM.
en HTGD 693 000 V0140 A 475

& WP4140
Blank Page
476 HTGD 693 000 V0140 A en

1.6 1BSE001377_-_LONGITUDINAL SECTION

1BSE001377_-_LONGITUDINAL SECTION
en HTGD 693 000 V0140 A 477

& WP4140
Blank Page
478 HTGD 693 000 V0140 A en

1.7 1BSE001405_B_P&ID STEAM TURBINE

1BSE001405_B_P&ID STEAM TURBINE
en HTGD 693 000 V0140 A 479

WP4110 & WP4140
1.7.1 1BSE001405_B_P&ID STEAM TURBINE_Page_2

1BSE001405_B_P&ID STEAM TURBINE_Page_2
480 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 481

WP4110 & WP4140

482 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 483

& WP4140
Blank Page
484 HTGD 693 000 V0140 A en

1.8 1BSE001637_-_CLEARANCE TABEL(HD) - ASSEMBLY

CLEARANCES - RADIALAXIAL
1BSE001637_-_CLEARANCE TABEL(HD) - ASSEMBLY CLEARANCES -

RADIALAXIAL
en HTGD 693 000 V0140 A 485

1.8.1 1BSE001637_-_CLEARANCE TABEL(HD) - ASSEMBLY CLEARANCES -

RADIALAXIAL_Page_02
RADIALAXIAL_Page_02
486 HTGD 693 000 V0140 A en


RADIALAXIAL_Page_03
RADIALAXIAL_Page_03
en HTGD 693 000 V0140 A 487


RADIALAXIAL_Page_04
RADIALAXIAL_Page_04
488 HTGD 693 000 V0140 A en


RADIALAXIAL_Page_05
RADIALAXIAL_Page_05
en HTGD 693 000 V0140 A 489


RADIALAXIAL_Page_06
RADIALAXIAL_Page_06
490 HTGD 693 000 V0140 A en


RADIALAXIAL_Page_07
RADIALAXIAL_Page_07
en HTGD 693 000 V0140 A 491


RADIALAXIAL_Page_08
RADIALAXIAL_Page_08
492 HTGD 693 000 V0140 A en


RADIALAXIAL_Page_09
RADIALAXIAL_Page_09
en HTGD 693 000 V0140 A 493


RADIALAXIAL0
RADIALAXIAL0
494 HTGD 693 000 V0140 A en


RADIALAXIAL1
RADIALAXIAL1
en HTGD 693 000 V0140 A 495


RADIALAXIAL2
RADIALAXIAL2
496 HTGD 693 000 V0140 A en


RADIALAXIAL3
RADIALAXIAL3
en HTGD 693 000 V0140 A 497


RADIALAXIAL4
RADIALAXIAL4
498 HTGD 693 000 V0140 A en


RADIALAXIAL5
RADIALAXIAL5
en HTGD 693 000 V0140 A 499


RADIALAXIAL6
RADIALAXIAL6
500 HTGD 693 000 V0140 A en

1.9 1BSE001713_-_HYDR. AND LUBE OIL UNIT
1BSE001713_-_HYDR. AND LUBE OIL UNIT
en HTGD 693 000 V0140 A 501

& WP4140
Blank Page
502 HTGD 693 000 V0140 A en

1.10 1BSE001715_A_P&ID LUBE OIL PURIFIER

1BSE001715_A_P&ID LUBE OIL PURIFIER
en HTGD 693 000 V0140 A 503

& WP4140
Blank Page
504 HTGD 693 000 V0140 A en

1.11 1BSE001848_-_EXPANS. SLEEVE COUPLING

1BSE001848_-_EXPANS. SLEEVE COUPLING
en HTGD 693 000 V0140 A 505

& WP4140
Blank Page
506 HTGD 693 000 V0140 A en

1.12 1BSE001957_-_ADJUSTMENT DIAGRAM CV1

1BSE001957_-_ADJUSTMENT DIAGRAM CV1
en HTGD 693 000 V0140 A 507

& WP4140
Blank Page
508 HTGD 693 000 V0140 A en

1.13 1BSE001958_-_ADJUSTMENT DIAGRAM NDK

1BSE001958_-_ADJUSTMENT DIAGRAM NDK
en HTGD 693 000 V0140 A 509

& WP4140
Blank Page
510 HTGD 693 000 V0140 A en

1.14 1BSE501022_B_LEGEND FOR P&ID ST
1BSE501022_B_LEGEND FOR P&ID ST
en HTGD 693 000 V0140 A 511

1.14.1 1BSE501022_B_LEGEND FOR P&ID ST_Page_02

1BSE501022_B_LEGEND FOR P&ID ST_Page_02
512 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 513


514 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 515


516 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 517


518 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 519

1.14.9 1BSE501022_B_LEGEND FOR P&ID ST0

1BSE501022_B_LEGEND FOR P&ID ST0
520 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 521


522 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 523


524 HTGD 693 000 V0140 A en

1.15 1BSE501152_-_DESCRIPTON OF ST SYSTEMS

1BSE501152_-_DESCRIPTON OF ST SYSTEMS
en HTGD 693 000 V0140 A 525

1.15.1 1BSE501152_-_DESCRIPTON OF ST SYSTEMS_Page_02

1BSE501152_-_DESCRIPTON OF ST SYSTEMS_Page_02
526 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 527


528 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 529


530 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 531


532 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 533

1.15.9 1BSE501152_-_DESCRIPTON OF ST SYSTEMS0

1BSE501152_-_DESCRIPTON OF ST SYSTEMS0
534 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 535


536 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 537


538 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 539


540 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 541


542 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 543

Blank Page
544 HTGD 693 000 V0140 A en

1.16 1BSE501156_A_I_O LIST ST

1BSE501156_A_I_O LIST ST
en HTGD 693 000 V0140 A 545

1.16.1 1BSE501156_A_I_O LIST ST_Page_2

1BSE501156_A_I_O LIST ST_Page_2
546 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 547


548 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 549


550 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 551


552 HTGD 693 000 V0140 A en

1.17 1BSE501157_B_START & OPER. INSTRUCTION

1BSE501157_B_START & OPER. INSTRUCTION
en HTGD 693 000 V0140 A 553

1.17.1 1BSE501157_B_START & OPER. INSTRUCTION_Page_02

1BSE501157_B_START & OPER. INSTRUCTION_Page_02
554 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 555


556 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 557


558 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 559


560 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 561

1.17.9 1BSE501157_B_START & OPER. INSTRUCTION0

1BSE501157_B_START & OPER. INSTRUCTION0
562 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 563


564 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 565


566 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 567


568 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 569


570 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 571


572 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 573


574 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 575


576 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 577


578 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 579


580 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 581


582 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 583


584 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 585


586 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 587


588 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 589


590 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 591


592 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 593


594 HTGD 693 000 V0140 A en

1.18 1BSE501163_-_DESCR. OF ST CONTROLLER

1BSE501163_-_DESCR. OF ST CONTROLLER
en HTGD 693 000 V0140 A 595

1.18.1 1BSE501163_-_DESCR. OF ST CONTROLLER_Page_02

1BSE501163_-_DESCR. OF ST CONTROLLER_Page_02
596 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 597


598 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 599


600 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 601


602 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 603

1.18.9 1BSE501163_-_DESCR. OF ST CONTROLLER0

1BSE501163_-_DESCR. OF ST CONTROLLER0
604 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 605


606 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 607

Blank Page
608 HTGD 693 000 V0140 A en

1.19 1BSE501424_A_LEGEND P&ID PURIFIER

1BSE501424_A_LEGEND P&ID PURIFIER
en HTGD 693 000 V0140 A 609

1.19.1 1BSE501424_A_LEGEND P&ID PURIFIER_Page_2

1BSE501424_A_LEGEND P&ID PURIFIER_Page_2
610 HTGD 693 000 V0140 A en

1.19.2 1BSE501424_A_LEGEND P&ID PURIFIER_Page_3

1BSE501424_A_LEGEND P&ID PURIFIER_Page_3
en HTGD 693 000 V0140 A 611

Blank Page
612 HTGD 693 000 V0140 A en

1.20 1BSE501638_-_BALANCING WEIGHT

DISTRIBUTION(MDG100K) - MN-ROTOR
1BSE501638_-_BALANCING WEIGHT DISTRIBUTION(MDG100K) - MN-ROTOR
en HTGD 693 000 V0140 A 613

Blank Page
614 HTGD 693 000 V0140 A en

MA - Test
1.21 HTCT692082V0001- - General Bolted Connections, Tightening

Torques and Prestressing Forces
HTCT692082V0001- - General Bolted Connections, Tightening Torques and
Prestressing Forces
en HTGD 693 000 V0140 A

615
1.21.1 HTCT692082V0001- - General Bolted Connections, Tightening Torques

and Prestressing Forces_Page_2
Prestressing Forces_Page_2
616 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 617


618 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 619


620 HTGD 693 000 V0140 A en

1.22 HTGD499340_-_CLEARANCE CHECH OF HOLD-DOWN

BAR(TBS) - TC-BEARING PEDESTAL
HTGD499340_-_CLEARANCE CHECH OF HOLD-DOWN BAR(TBS) - TC-
BEARING PEDESTAL
en HTGD 693 000 V0140 A 621

Blank Page
622 HTGD 693 000 V0140 A en

1.23 HTGD499343_A_CLEARANCES OF OIL SHIELDS(TBS-IBS-

DBS-NBS-EBS) - TC-BEARING PEDESTAL
HTGD499343_A_CLEARANCES OF OIL SHIELDS(TBS-IBS-DBS-NBS-EBS) - TC-
BEARING PEDESTAL
en HTGD 693 000 V0140 A 623

Blank Page
624 HTGD 693 000 V0140 A en

1.24 HTGD499345_-_CLEARANCE SPEED SENSOR(TBS1) - TC-

BEARING PEDESTAL
HTGD499345_-_CLEARANCE SPEED SENSOR(TBS1) - TC-BEARING PEDESTAL
en HTGD 693 000 V0140 A 625

Blank Page
626 HTGD 693 000 V0140 A en

1.25 HTGD630064_A_ITH110 HYDR.STRETCH.BOLTS(1)

HTGD630064_A_ITH110 HYDR.STRETCH.BOLTS(1)
en HTGD 693 000 V0140 A 627

1.25.1 HTGD630064_A_ITH110 HYDR.STRETCH.BOLTS(1)_Page_2

HTGD630064_A_ITH110 HYDR.STRETCH.BOLTS(1)_Page_2
628 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 629


630 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 631


632 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 633

Blank Page
634 HTGD 693 000 V0140 A en

1.26 HTGD630122_C_MA-LUBE OIL SYSTEM

HTGD630122_C_MA-LUBE OIL SYSTEM
en HTGD 693 000 V0140 A 635

1.26.1 HTGD630122_C_MA-LUBE OIL SYSTEM_Page_02

HTGD630122_C_MA-LUBE OIL SYSTEM_Page_02
636 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 637


638 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 639


640 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 641


642 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 643

1.26.9 HTGD630122_C_MA-LUBE OIL SYSTEM0

HTGD630122_C_MA-LUBE OIL SYSTEM0
644 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 645


646 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 647


648 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 649


650 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 651


652 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 653


654 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 655

Blank Page
656 HTGD 693 000 V0140 A en

1.27 HTGD630136_A_MA-VALVE STEM PACKING

HTGD630136_A_MA-VALVE STEM PACKING
en HTGD 693 000 V0140 A 657

1.27.1 HTGD630136_A_MA-VALVE STEM PACKING_Page_2

HTGD630136_A_MA-VALVE STEM PACKING_Page_2
658 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 659


660 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 661

Blank Page
662 HTGD 693 000 V0140 A en

1.28 HTGD630147_B_TIGHTENING TORQUE

HTGD630147_B_TIGHTENING TORQUE
en HTGD 693 000 V0140 A 663

1.28.1 HTGD630147_B_TIGHTENING TORQUE_Page_2

HTGD630147_B_TIGHTENING TORQUE_Page_2
664 HTGD 693 000 V0140 A en

1.28.2 HTGD630147_B_TIGHTENING TORQUE_Page_3

HTGD630147_B_TIGHTENING TORQUE_Page_3
en HTGD 693 000 V0140 A 665

Blank Page
666 HTGD 693 000 V0140 A en

1.29 HTGD630178_B_FLUSHING PROCEDURE FAST

HTGD630178_B_FLUSHING PROCEDURE FAST
en HTGD 693 000 V0140 A 667

1.29.1 HTGD630178_B_FLUSHING PROCEDURE FAST_Page_02

HTGD630178_B_FLUSHING PROCEDURE FAST_Page_02
668 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 669


670 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 671


672 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 673


674 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 675

1.29.9 HTGD630178_B_FLUSHING PROCEDURE FAST0

HTGD630178_B_FLUSHING PROCEDURE FAST0
676 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 677


678 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 679


680 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 681


682 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 683


684 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 685


686 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 687


688 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 689


690 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 691


692 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 693


694 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 695

Blank Page
696 HTGD 693 000 V0140 A en

1.30 HTGD667183_A_ADJUSTMENT OF TURBINE

INSTRUMENT(VLA) - TC-BEARING PEDESTAL
HTGD667183_A_ADJUSTMENT OF TURBINE INSTRUMENT(VLA) - TC-BEARING
PEDESTAL
en HTGD 693 000 V0140 A 697

Blank Page
698 HTGD 693 000 V0140 A en


COMPLETE(FD-SSVM250 - CV1) - STOP VALVE
HTGD667205_-_MAIN STROKE CHECK VALVE BLOCK COMPLETE(FD-
SSVM250 - CV1) - STOP VALVE
en HTGD 693 000 V0140 A 699

Blank Page
700 HTGD 693 000 V0140 A en


COMPLETE(STVM200 - CV1) - CONTROL VALVE
HTGD667206_-_MAIN STROKE CHECK VALVE BLOCK COMPLETE(STVM200 -
CV1) - CONTROL VALVE
en HTGD 693 000 V0140 A 701

Blank Page
702 HTGD 693 000 V0140 A en

1.33 HTGD667229_-_CHECK OF CORRECT VALVE

ARRANGEMENT(MDG100K) - TURBINE COMPLETE
HTGD667229_-_CHECK OF CORRECT VALVE ARRANGEMENT(MDG100K) -
TURBINE COMPLETE
en HTGD 693 000 V0140 A 703

Blank Page
704 HTGD 693 000 V0140 A en

1.34 HTGD667230_-_IP-STEAM DUCT BOLT

PRESTRESS(MDG100K) - STEAM DUCT
HTGD667230_-_IP-STEAM DUCT BOLT PRESTRESS(MDG100K) - STEAM DUCT
en HTGD 693 000 V0140 A 705

Blank Page
706 HTGD 693 000 V0140 A en

1.35 HTGD667231_-_SWING ARM SUPPORT

ADJUSTMENT(MDG100K) - SPRING LOADED SUPPORT
HTGD667231_-_SWING ARM SUPPORT ADJUSTMENT(MDG100K) - SPRING
LOADED SUPPORT
en HTGD 693 000 V0140 A 707

Blank Page
708 HTGD 693 000 V0140 A en

1.36 HTGD667232_-_SET VALUES FOR STOP VALVE ASSEMBLY-

REASSEMBLY(CV1) - SET VALUES
HTGD667232_-_SET VALUES FOR STOP VALVE ASSEMBLY-
en HTGD 693 000 V0140 A 709

Blank Page
710 HTGD 693 000 V0140 A en

1.37 HTGD667233_-_SET VALUES FOR CONTROL VALVE

ASSEMBLY-REASSEMBLY(CV1) - SET VALUES
HTGD667233_-_SET VALUES FOR CONTROL VALVE ASSEMBLY-
en HTGD 693 000 V0140 A 711

Blank Page
712 HTGD 693 000 V0140 A en

1.38 HTGD667235_-_BOLT PRESTRESS IP-OUTER

CASING(MDG100K) - BOLT PRESTRESS
HTGD667235_-_BOLT PRESTRESS IP-OUTER CASING(MDG100K) - BOLT
PRESTRESS
en HTGD 693 000 V0140 A 713

Blank Page
714 HTGD 693 000 V0140 A en

1.39 HTGD667236_-_BOLT PRESTRESS LP-OUTER

CASING(NE41A) - BOLT PRESTRESS
HTGD667236_-_BOLT PRESTRESS LP-OUTER CASING(NE41A) - BOLT
PRESTRESS
en HTGD 693 000 V0140 A 715

Blank Page
716 HTGD 693 000 V0140 A en

1.40 HTGD667237_-_BOLT PRESTRESS IP-INNER

CASING(MDG100K) - BOLT PRESTRESS
HTGD667237_-_BOLT PRESTRESS IP-INNER CASING(MDG100K) - BOLT
PRESTRESS
en HTGD 693 000 V0140 A 717

Blank Page
718 HTGD 693 000 V0140 A en

1.41 HTGD667238_-_BOLT PRESTRESS LP-BLADE

CARRIER(NE41A) - BOLT PRESTRESS
HTGD667238_-_BOLT PRESTRESS LP-BLADE CARRIER(NE41A) - BOLT
PRESTRESS
en HTGD 693 000 V0140 A 719

Blank Page
720 HTGD 693 000 V0140 A en

1.42 HTGD667239_-_BOLT PRESTRESS VERTICAL

FLANGE(MDG100K) - BOLT PRESTRESS
HTGD667239_-_BOLT PRESTRESS VERTICAL FLANGE(MDG100K) - BOLT
PRESTRESS
en HTGD 693 000 V0140 A 721

Blank Page
722 HTGD 693 000 V0140 A en

1.43 HTGD667240_-_LEVELLING OF THE IP-LP OUTER

CASING(MDG100K-NE41A) - CASING LEVELLING
HTGD667240_-_LEVELLING OF THE IP-LP OUTER CASING(MDG100K-NE41A) -
CASING LEVELLING
en HTGD 693 000 V0140 A 723

Blank Page
724 HTGD 693 000 V0140 A en

1.44 HTGD667241_-_DIMENSIONAL CHECK OF INTERMEDIATE

PIPE(MDG100K) - INTERMEDIATE PIPE
HTGD667241_-_DIMENSIONAL CHECK OF INTERMEDIATE PIPE(MDG100K) -
INTERMEDIATE PIPE
en HTGD 693 000 V0140 A 725

Blank Page
726 HTGD 693 000 V0140 A en

1.45 HTGD667244_-_LP-GLAND SEAL RADIAL AND AXIAL

CLEARANCES(NE41A) - GLAND SEAL
HTGD667244_-_LP-GLAND SEAL RADIAL AND AXIAL CLEARANCES(NE41A) -
GLAND SEAL
en HTGD 693 000 V0140 A 727

1.45.1 HTGD667244_-_LP-GLAND SEAL RADIAL AND AXIAL

CLEARANCES(NE41A) - GLAND SEAL_Page_2
HTGD667244_-_LP-GLAND SEAL RADIAL AND AXIAL CLEARANCES(NE41A) -
GLAND SEAL_Page_2
728 HTGD 693 000 V0140 A en

1.46 HTGD667246_A_POSITION CHECK OF INNER PARTS IN IP-

OUTER CASING(MDG100K) - POSITION CHECK
HTGD667246_A_POSITION CHECK OF INNER PARTS IN IP-OUTER
CASING(MDG100K) - POSITION CHECK
en HTGD 693 000 V0140 A 729

Blank Page
730 HTGD 693 000 V0140 A en

1.47 HTGD667247_-_IP-INNER CASING FIXING

ELEMENTS(MDG100K) - ADJUSTING ELEMENT
HTGD667247_-_IP-INNER CASING FIXING ELEMENTS(MDG100K) - ADJUSTING
ELEMENT
en HTGD 693 000 V0140 A 731

Blank Page
732 HTGD 693 000 V0140 A en

1.48 HTGD667248_-_IP-INNER CASING FIXING

ELEMENTS(MDG100K) - ADJUSTING ELEMENT
HTGD667248_-_IP-INNER CASING FIXING ELEMENTS(MDG100K) - ADJUSTING
ELEMENT
en HTGD 693 000 V0140 A 733

Blank Page
734 HTGD 693 000 V0140 A en

1.49 HTGD667249_-_IP-INNER CASING FIXING ELEMENT

HORIZONTAL(MDG100K) - ADJUSTING ELEMENT
HTGD667249_-_IP-INNER CASING FIXING ELEMENT HORIZONTAL(MDG100K) -
ADJUSTING ELEMENT
en HTGD 693 000 V0140 A 735

Blank Page
736 HTGD 693 000 V0140 A en

1.50 HTGD667250_A_IP-INNER CASING FIXING ELEMENT

HORIZONTAL(MDG100K) - ADJUSTING ELEMENT
HTGD667250_A_IP-INNER CASING FIXING ELEMENT HORIZONTAL(MDG100K)
- ADJUSTING ELEMENT
en HTGD 693 000 V0140 A 737

Blank Page
738 HTGD 693 000 V0140 A en

1.51 HTGD667251_-_LP-BLADE CARRIER FIXING HORIZONTAL-

VERTICAL(NE41A) - ADJUSTING ELEMENT
HTGD667251_-_LP-BLADE CARRIER FIXING HORIZONTAL-VERTICAL(NE41A) -
ADJUSTING ELEMENT
en HTGD 693 000 V0140 A 739

Blank Page
740 HTGD 693 000 V0140 A en

1.52 HTGD667252_-_POSITION CHECK OF IP-STEAM

DUCT(MDG100K) - STEAM DUCT
HTGD667252_-_POSITION CHECK OF IP-STEAM DUCT(MDG100K) - STEAM
DUCT
en HTGD 693 000 V0140 A 741

Blank Page
742 HTGD 693 000 V0140 A en

1.53 HTGD667254_-_IP-TURBINE COMPLETE CHECK OF THE

CONNECTION DIMENSIONS(MDG100K) - CONNECTION
DIMENSION
HTGD667254_-_IP-TURBINE COMPLETE CHECK OF THE CONNECTION
DIMENSIONS(MDG100K) - CONNECTION DIMENSION
en HTGD 693 000 V0140 A 743

Blank Page
744 HTGD 693 000 V0140 A en

1.54 HTGD667255_-_CHECK ROTOR POSITION TO INNER

CASING(MDG100K) - ROTOR_INNER CASING
HTGD667255_-_CHECK ROTOR POSITION TO INNER CASING(MDG100K) -
ROTOR_INNER CASING
en HTGD 693 000 V0140 A 745

Blank Page
746 HTGD 693 000 V0140 A en

1.55 HTGD667256_-_CHECK ROTOR POSITION TO OUTER

CASING(MDG100K) - ROTOR_OUTER CASING
HTGD667256_-_CHECK ROTOR POSITION TO OUTER CASING(MDG100K) -
ROTOR_OUTER CASING
en HTGD 693 000 V0140 A 747

Blank Page
748 HTGD 693 000 V0140 A en

1.56 HTGD667257_-_POSSIBLE DISPLACEMENT AXIAL ROTOR

TO CASING(MDG100K-NE41A) - ROTOR_CASING
HTGD667257_-_POSSIBLE DISPLACEMENT AXIAL ROTOR TO
CASING(MDG100K-NE41A) - ROTOR_CASING
en HTGD 693 000 V0140 A 749

Blank Page
750 HTGD 693 000 V0140 A en

1.57 HTGD667259_-_PRE-STRESSED FOUNDATION

BOLT(GENERAL - MA) - FOUNDATION BOLTS
HTGD667259_-_PRE-STRESSED FOUNDATION BOLT(GENERAL - MA) -
FOUNDATION BOLTS
en HTGD 693 000 V0140 A 751

Blank Page
752 HTGD 693 000 V0140 A en

1.58 HTGD667260_-_POSITION CHECK(NE41A) - BLADE CARRIER

POSITION - RELATIVE TO ROTOR
HTGD667260_-_POSITION CHECK(NE41A) - BLADE CARRIER POSITION -
RELATIVE TO ROTOR
en HTGD 693 000 V0140 A 753

Blank Page
754 HTGD 693 000 V0140 A en

1.59 HTGD667261_-_LP-TURBINE FOUNDATION KEY

FIXING(NE41A) - LP-TURBINE FOUNDATI0N
HTGD667261_-_LP-TURBINE FOUNDATION KEY FIXING(NE41A) - LP-TURBINE
FOUNDATI0N
en HTGD 693 000 V0140 A 755

Blank Page
756 HTGD 693 000 V0140 A en

1.60 HTGD667262_-_OUTER CASING CHECK THE ADJUSTING

CLEARANCES OF THE SUPPORT(NE41A) - LP-SUPPORT
HTGD667262_-_OUTER CASING CHECK THE ADJUSTING CLEARANCES OF
THE SUPPORT(NE41A) - LP-SUPPORT
en HTGD 693 000 V0140 A 757

1.60.1 HTGD667262_-_OUTER CASING CHECK THE ADJUSTING

CLEARANCES OF THE SUPPORT(NE41A) - LP-SUPPORT_Page_2
HTGD667262_-_OUTER CASING CHECK THE ADJUSTING CLEARANCES OF
THE SUPPORT(NE41A) - LP-SUPPORT_Page_2
758 HTGD 693 000 V0140 A en

1.61 HTGD667263_-_BEARING CLEARANCE AND OIL POCKET

CHECK(R1T - D315) - TC-JOURNAL BEARING
HTGD667263_-_BEARING CLEARANCE AND OIL POCKET CHECK(R1T - D315) -
TC-JOURNAL BEARING
en HTGD 693 000 V0140 A 759

Blank Page
760 HTGD 693 000 V0140 A en

1.62 HTGD667264_-_ADJUSTING DIMENSIONS FOR

DIFFERENTIAL EXPANSION() - DIFFERENTIAL EXPANSION
HTGD667264_-_ADJUSTING DIMENSIONS FOR DIFFERENTIAL EXPANSION() -
DIFFERENTIAL EXPANSION
en HTGD 693 000 V0140 A 761

Blank Page
762 HTGD 693 000 V0140 A en

1.63 HTGD667265_-_BACKLASH TEST OF MAIN OIL

PUMP(MAV21) - LP-BEARING SECTION
HTGD667265_-_BACKLASH TEST OF MAIN OIL PUMP(MAV21) - LP-BEARING
SECTION
en HTGD 693 000 V0140 A 763

Blank Page
764 HTGD 693 000 V0140 A en

1.64 HTGD667266_-_LP-EXHAUST CONE(NE41A) - POSITION TEST

- ROTOR TO EXHAUST CONE
HTGD667266_-_LP-EXHAUST CONE(NE41A) - POSITION TEST - ROTOR TO
EXHAUST CONE
en HTGD 693 000 V0140 A 765

Blank Page
766 HTGD 693 000 V0140 A en

1.65 HTGD667267_-_CLEARANCE CHECK OF OIL SHIELD(NE41A)

- LP-BEARING PEDESTAL
HTGD667267_-_CLEARANCE CHECK OF OIL SHIELD(NE41A) - LP-BEARING
PEDESTAL
en HTGD 693 000 V0140 A 767

Blank Page
768 HTGD 693 000 V0140 A en

1.66 HTGD667268_-_TURBINE FOUNDATION LEVELLING

POINTS(GENERAL - MA) - TC-LEVELLING
HTGD667268_-_TURBINE FOUNDATION LEVELLING POINTS(GENERAL - MA) -
TC-LEVELLING
en HTGD 693 000 V0140 A 769

Blank Page
770 HTGD 693 000 V0140 A en

1.67 HTGD667269_-_DISASSEMBLY AND ASSEMBLY OF

ROTORS(GENERAL - MA) - TC-SHAFT LINE
HTGD667269_-_DISASSEMBLY AND ASSEMBLY OF ROTORS(GENERAL - MA) -
TC-SHAFT LINE
en HTGD 693 000 V0140 A 771

Blank Page
772 HTGD 693 000 V0140 A en

1.68 HTGD667270_A_EXPANSION SLEEVE COUPLING FOR IP-

LP(SHK 400) - TC-EXPANSION SLEEVE
HTGD667270_A_EXPANSION SLEEVE COUPLING FOR IP-LP(SHK 400) - TC-
EXPANSION SLEEVE
en HTGD 693 000 V0140 A 773

1.68.1 HTGD667270_A_EXPANSION SLEEVE COUPLING FOR IP-LP(SHK 400) -

TC-EXPANSION SLEEVE_Page_2
HTGD667270_A_EXPANSION SLEEVE COUPLING FOR IP-LP(SHK 400) - TC-
EXPANSION SLEEVE_Page_2
774 HTGD 693 000 V0140 A en

1.69 HTGD667271_-_DISPOSITION OF SLINGS(VLB) - TC-BEARING

PEDESTAL
HTGD667271_-_DISPOSITION OF SLINGS(VLB) - TC-BEARING PEDESTAL
en HTGD 693 000 V0140 A 775

Blank Page
776 HTGD 693 000 V0140 A en

1.70 HTGD667272_-_CLEARANCE CHECK BEARING PEDESTAL-

BASE PLATE(VLB) - TC-BEARING PEDESTAL
HTGD667272_-_CLEARANCE CHECK BEARING PEDESTAL-BASE PLATE(VLB) -
TC-BEARING PEDESTAL
en HTGD 693 000 V0140 A 777

1.70.1 HTGD667272_-_CLEARANCE CHECK BEARING PEDESTAL-BASE

PLATE(VLB) - TC-BEARING PEDESTAL_Page_2
HTGD667272_-_CLEARANCE CHECK BEARING PEDESTAL-BASE PLATE(VLB) -
TC-BEARING PEDESTAL_Page_2
778 HTGD 693 000 V0140 A en

1.71 HTGD667273_-_CHECK THE BEARING CLEARANCE THRUST

AND JOURNAL BEARING(VLB - �355) - TC-BEARING
PEDESTAL
HTGD667273_-_CHECK THE BEARING CLEARANCE THRUST AND JOURNAL
BEARING(VLB - �355) - TC-BEARING PEDESTAL
en HTGD 693 000 V0140 A 779

1.71.1 HTGD667273_-_CHECK THE BEARING CLEARANCE THRUST AND

JOURNAL BEARING(VLB - �355) - TC-BEARING PEDESTAL_Page_2
HTGD667273_-_CHECK THE BEARING CLEARANCE THRUST AND JOURNAL
BEARING(VLB - �355) - TC-BEARING PEDESTAL_Page_2
780 HTGD 693 000 V0140 A en

1.72 HTGD667274_-_ROTOR POSITION IN BEARING

PEDESTAL(VLB) - TC-BEARING PEDESTAL
HTGD667274_-_ROTOR POSITION IN BEARING PEDESTAL(VLB) - TC-BEARING
PEDESTAL
en HTGD 693 000 V0140 A 781

Blank Page
782 HTGD 693 000 V0140 A en

1.73 HTGD667275_-_AXIAL CLEARANCE MEASUREMENT OF

BEARING PEDESTAL-TURBINE(VLB) - TC-BEARING
PEDESTAL
HTGD667275_-_AXIAL CLEARANCE MEASUREMENT OF BEARING PEDESTAL-
TURBINE(VLB) - TC-BEARING PEDESTAL
en HTGD 693 000 V0140 A 783

Blank Page
784 HTGD 693 000 V0140 A en

1.74 HTGD667276_-_CLEARANCE MEASUREMENT HOLD-DOWN

BAR TURBINE-BEARING PEDESTAL(VLB) - TC-BEARING
PEDESTAL
HTGD667276_-_CLEARANCE MEASUREMENT HOLD-DOWN BAR TURBINE-
BEARING PEDESTAL(VLB) - TC-BEARING PEDESTAL
en HTGD 693 000 V0140 A 785

Blank Page
786 HTGD 693 000 V0140 A en

1.75 HTGD667277_-_CLEARANCE MEASUREMENT VERTICAL

KEY BEARING PEDESTAL-TURBINE(VLB) - TC-BEARING
PEDESTAL
HTGD667277_-_CLEARANCE MEASUREMENT VERTICAL KEY BEARING
PEDESTAL-TURBINE(VLB) - TC-BEARING PEDESTAL
en HTGD 693 000 V0140 A 787

Blank Page
788 HTGD 693 000 V0140 A en

1.76 HTGD667459_-_ROTOR POSITION NE-BEARING

PEDESTAL(NE ) - NE-BEARING PEDESTAL
HTGD667459_-_ROTOR POSITION NE-BEARING PEDESTAL(NE ) - NE-
BEARING PEDESTAL
en HTGD 693 000 V0140 A 789

Blank Page
790 HTGD 693 000 V0140 A en

1.77 HTGD672031_B_INSPECTION PLANS

HTGD672031_B_INSPECTION PLANS
en HTGD 693 000 V0140 A 791

1.77.1 HTGD672031_B_INSPECTION PLANS_Page_2

HTGD672031_B_INSPECTION PLANS_Page_2
792 HTGD 693 000 V0140 A en

1.78 HTGD672059_D_INSPECTION REC.

HTGD672059_D_INSPECTION REC.
en HTGD 693 000 V0140 A 793

1.78.1 HTGD672059_D_INSPECTION REC._Page_2

HTGD672059_D_INSPECTION REC._Page_2
794 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 795


796 HTGD 693 000 V0140 A en

1.79 HTGD479232_A_() - HYDRAULIC PRESTRESS

HTGD479232_A_() - HYDRAULIC PRESTRESS
en HTGD 693 000 V0140 A 797

Blank Page_
798 HTGD 693 000 V0140 A en

1.80 HTGD479469_A_() - FUNCTIONAL TEST

HTGD479469_A_() - FUNCTIONAL TEST
en HTGD 693 000 V0140 A 799

Blank Page_
800 HTGD 693 000 V0140 A en

1.81 HTGD479470_A_() - FUNCTIONAL TEST

HTGD479470_A_() - FUNCTIONAL TEST
en HTGD 693 000 V0140 A 801

Blank Page_
802 HTGD 693 000 V0140 A en

1.82 HTGD691538D0401_-_Hand Lever Pressure Pump Unit

HTGD691538D0401_-_Hand Lever Pressure Pump Unit
en HTGD 693 000 V0140 A 803

1.82.1 HTGD691538D0401_-_Hand Lever Pressure Pump Unit_Page_2

HTGD691538D0401_-_Hand Lever Pressure Pump Unit_Page_2
804 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 805


806 HTGD 693 000 V0140 A en

1.83 HTGD691538D0410_-_High Pressure Pump Unit

HTGD691538D0410_-_High Pressure Pump Unit
en HTGD 693 000 V0140 A 807

1.83.1 HTGD691538D0410_-_High Pressure Pump Unit_Page_2

HTGD691538D0410_-_High Pressure Pump Unit_Page_2
808 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 809


810 HTGD 693 000 V0140 A en

1.84 HTGD691538D0413- - High Pressure Hand Lever Pump

HTGD691538D0413- - High Pressure Hand Lever Pump
en HTGD 693 000 V0140 A 811

1.84.1 HTGD691538D0413- - High Pressure Hand Lever Pump_Page_2

HTGD691538D0413- - High Pressure Hand Lever Pump_Page_2
812 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 813


814 HTGD 693 000 V0140 A en

1.85 HTGD691538D0414- - High Pressure Pump Unit

HTGD691538D0414- - High Pressure Pump Unit
en HTGD 693 000 V0140 A 815

1.85.1 HTGD691538D0414- - High Pressure Pump Unit_Page_2

HTGD691538D0414- - High Pressure Pump Unit_Page_2
816 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 817


818 HTGD 693 000 V0140 A en

1.86 HTGD691539V0001A - Flared Tube Fitting

HTGD691539V0001A - Flared Tube Fitting
en HTGD 693 000 V0140 A 819

1.86.1 HTGD691539V0001A - Flared Tube Fitting_Page_02

HTGD691539V0001A - Flared Tube Fitting_Page_02
820 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

821

822 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

823

824 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

825

826 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

827
1.86.9 HTGD691539V0001A - Flared Tube Fitting0

HTGD691539V0001A - Flared Tube Fitting0
828 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 829


830 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 831


832 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 833

Blank Page_
834 HTGD 693 000 V0140 A en

1.87 HTGD691613V0002A - Vacuum Breaking Valve

HTGD691613V0002A - Vacuum Breaking Valve
en HTGD 693 000 V0140 A 835

1.87.1 HTGD691613V0002A - Vacuum Breaking Valve_Page_02

HTGD691613V0002A - Vacuum Breaking Valve_Page_02
836 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 837


838 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 839


840 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 841


842 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 843

1.87.9 HTGD691613V0002A - Vacuum Breaking Valve0

HTGD691613V0002A - Vacuum Breaking Valve0
844 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

845

846 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

847

848 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

849

850 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

851

852 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A

853

854 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 855


856 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 857


858 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 859


860 HTGD 693 000 V0140 A en

1.88 HTGD691631V0002A - Globe Valve

HTGD691631V0002A - Globe Valve
en HTGD 693 000 V0140 A 861

1.88.1 HTGD691631V0002A - Globe Valve_Page_02

HTGD691631V0002A - Globe Valve_Page_02
862 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 863


864 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 865


866 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 867


868 HTGD 693 000 V0140 A en


en HTGD 693 000 V0140 A 869

1.88.9 HTGD691631V0002A - Globe Valve0

HTGD691631V0002A - Globe Valve0
870 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 871


872 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 873


874 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 875


876 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 877


878 HTGD 693 000 V0140 A en

MA - Test

en HTGD 693 000 V0140 A 879


880 HTGD 693 000 V0140 A en

en HTGD 693 000 V0140 A 881

Blank Page
Pr�fprotokolle
882 HTGD 693 000 V0140 A en

MA - Instrumentation List
en HTGD 693 000 V0140 A 883

Revision History
total :
- - (466)
884 HTGD 693 000 V0140 A en

Contents
1 INSTRUMENT
LIST ..............................................................................
.............................................893
1.1 MAA10CF001 -
PLUG ..............................................................................
............. 893
1.2 MAA10CP001 - PRESSURE
TRANSMITTER....................................................... 893
1.3 MAA10CP002 - ROOT
VALVE .............................................................................
. 894
1.4 MAA10CP031 - TAPPING
POINT ......................................................................... 894
1.5 MAA10CT005A - 1xTC. TEMP
TRANSM .............................................................. 895
1.6 MAA10CT005B - 1xTC. TEMP
TRANSM .............................................................. 895
1.7 MAA10CT005C - 1xTC. TEMP
TRANSM.............................................................. 896
1.8 MAA10CT010 - 3xTC. TEMP
TRANSM ................................................................ 896
1.9 MAA10CT026 -
THERMOWELL.........................................................................
... 897
1.10 MAA10CT032 -
THERMOWELL.........................................................................
... 897
1.11 MAA10CT033 -
THERMOWELL.........................................................................
... 898
1.12 MAA12CG001 - POSITION
TRANSMITTER......................................................... 898
TRANSMITTER......................................................... 899
TRANSMITTER......................................................... 899
1.15 MAC10CG101 - LIMIT
SWITCH ............................................................................
900
SWITCH ............................................................................
900
1.17 MAC10CP001 - PRESSURE
TRANSMITTER ...................................................... 901
1.18 MAC10CP002 - ROOT
VALVE..............................................................................
901
1.19 MAC10CP006 - ROOT
VALVE..............................................................................
902
TRANSMITTER ...................................................... 902
TRANSMITTER ...................................................... 903
TRANSMITTER ...................................................... 903
1.23 MAC10CP071 - TAPPING
POINT ......................................................................... 904
POINT ......................................................................... 904
POINT ......................................................................... 905
POINT ......................................................................... 905
1.27 MAC10CT010 - 3xTC. TEMP
TRANSM ................................................................ 906
en HTGD 693 000 V0140 A

885
WP4140
1.28 MAC10CT021 - 1xTC. TEMP

TRANSM ................................................................ 906
1.29 MAC10CT081 - 1xTC TEMP
TRANSM ................................................................. 907
1.30 MAC10CT082 - TEMPERATURE
INDICATOR ..................................................... 907
1.31 MAC10CY011 - DIFF EXP
PROBE....................................................................... 908
1.32 MAC10CY012 - DIFF EXP
PROBE....................................................................... 908
1.33 MAC31CG011 - POSITION
TRANSMITTER ........................................................ 909
1.34 MAC31CG031 - POSITION
TRANSMITTER ........................................................ 909
SWITCH............................................................................
910
SWITCH............................................................................
910
SWITCH............................................................................
911
SWITCH............................................................................
911
POINT......................................................................... 912
1.40 MAD20CS001 - SPEED
PROBE...........................................................................
912
PROBE...........................................................................
913
PROBE...........................................................................
913
1.43 MAD20CY004 - DISPL
TRANSDUCER ................................................................ 914
1.44 MAD20CY011 - THRUST POS
PROBE................................................................ 914
1.45 MAD20CY012 - THRUST POS
PROBE................................................................ 915
1.46 MAD20CY021 -
PROXPAC ...........................................................................
........ 915
1.47 MAD20CY022 -
PROXPAC ...........................................................................
........ 916
1.48 MAD20CY025 -
PROXPAC ...........................................................................
........ 916
1.49 MAD21CT001 - 2xTC. TEMP
TRANSM ................................................................ 917
TRANSM ................................................................ 917
TRANSM ................................................................ 918
TRANSM ................................................................ 918
TRANSM ................................................................ 919
TRANSM ................................................................ 919
1.55 MAD50CY021 - SHAFT VIB
PROBE .................................................................... 920
1.56 MAD50CY022 - SHAFT VIB
PROBE .................................................................... 920
886 HTGD 693 000 V0140 A

en

TRANSM ................................................................ 921
TRANSM ................................................................ 921
1.59 MAK80CG005 - LIMIT
SWITCH ............................................................................
922
SWITCH ............................................................................
922
SWITCH ............................................................................
923
SWITCH ............................................................................
923
SWITCH ............................................................................
924
1.64 MAK80EE211 - INDICATION TRNGR
POS .......................................................... 924
1.65 MAV02CL001 - LEVEL
SENSOR ..........................................................................
925
1.66 MAV02CL001A - LEVEL
INDICATOR ................................................................... 925
1.67 MAV02CP001 - TAPPING
POINT ......................................................................... 926
1.68 MAV02CT001 - TEMPERATURE
GAUGE ............................................................ 926
1.69 MAV21CP011 - PRESSURE
GAUGE ................................................................... 927
INDICATOR ............................................................ 927
INDICATOR ............................................................ 928
GAUGE ............................................................ 928
GAUGE ............................................................ 929
1.74 MAV23CP001 - DIFF. PRESS.
ALARM ................................................................ 929
1.75 MAV23CP001A - DIFF. PRESS.
INDIC................................................................. 930
1.76 MAV40CP002 - ROOT
VALVE .............................................................................
. 930
TRANSMITTER....................................................... 931
TRANSMITTER....................................................... 931
TRANSMITTER....................................................... 932
VALVE .............................................................................
. 932
VALVE .............................................................................
. 933
POINT ......................................................................... 933
INDICATOR ............................................................ 934
INDICATOR ............................................................ 934
INDICATOR ............................................................ 935
en HTGD 693 000 V0140 A

887
WP4140

POINT ......................................................................... 935
GAUGE............................................................ 936
1.88 MAV40CT002 - TEMP.
TRANSMITTER ............................................................... 936
INDICATOR ............................................................ 937
POINT ......................................................................... 937
POINT ......................................................................... 938
GAUGE............................................................ 938
1.93 MAV70CT023 - TEMP.
TRANSMITTER ............................................................... 939
GAUGE............................................................ 939
1.95 MAV70CT053 - TEMP.
TRANSMITTER ............................................................... 940
1.96 MAV91CE001 - E OIL
CENTRIF ...........................................................................
940
1.97 MAV91CE002 - E OIL
CENTRIF ...........................................................................
941
1.98 MAV91CE003 - E OIL
CENTRIF ...........................................................................
941
1.99 MAV91CF001 - F UPSTR OIL
CNTFG ................................................................. 942
1.100 MAV91CL001 - L CNTFG WASTE
TANK ............................................................. 942
1.101 MAV91CT002 - T OIL
HEATER ............................................................................
943
1.102 MAV91CT006 - T UPSTR OIL
CNTFG ................................................................. 943
1.103 MAW10CG011 - POSITION
TRANSMITTER........................................................ 944
1.104 MAW10CP001 - PRESSURE
INDICATOR ........................................................... 944
1.105 MAW15CG061 - POSITION
TRANSMITTER........................................................ 945
1.106 MAW15CP001 - PRESSURE
TRANSMITTER ..................................................... 945
1.107 MAW15CP001A - PRESSURE
GAUGE................................................................ 946
1.108 MAW15CP002 - TAPPING
POINT ........................................................................ 946
POINT ........................................................................ 947
1.110 MAW15CP011 -
DIFF.PRESS.GAUGE.................................................................
947
1.111 MAW15CT001 - 2xTC. TEMP
TRANSM ............................................................... 948
1.112 MAW15CT002 - TEMPERATURE
GAUGE ........................................................... 948
1.113 MAW15CT003 - TEMPERATURE
GAUGE ........................................................... 949
1.114 MAW30CL001 - LIQUID LEVEL
GAUGE .............................................................. 949
888 HTGD 693 000 V0140 A

en
1.115 MAW30CP001 - ROOT

VALVE .............................................................................
950
1.116 MAW30CP002 - ROOT
VALVE .............................................................................
950
POINT ........................................................................ 951
1.118 MAW30CT002 -
THERMOWELL.........................................................................
.. 951
1.119 MAW30CT011 -
THERMOWELL.........................................................................
.. 952
1.120 MAW30CT012 -
THERMOWELL.........................................................................
.. 952
1.121 MAX00EW011 - EMERG STOP
SWITCH ............................................................. 953
SWITCH ............................................................. 953
SWITCH ............................................................. 954
SWITCH ............................................................. 954
SWITCH ............................................................. 955
SWITCH ............................................................. 955
1.127 MAX11CP001 - PRESSURE
GAUGE ................................................................... 956
GAUGE ................................................................... 956
TRANSMITTER....................................................... 957
GAUGE ................................................................... 957
1.131 MAX13CP001 - DIFF. PRESS.
ALARM ................................................................ 958
1.132 MAX13CP001A - DIFF. PRESS.
INDIC................................................................. 958
INDICATOR ............................................................ 959
1.134 MAX16CP002 - TAPPING
POINT ......................................................................... 959
1.135 MAX44CG001 - LIMIT
SWITCH ............................................................................
960
TRANSMITTER....................................................... 960
TRANSMITTER....................................................... 961
TRANSMITTER....................................................... 961
1.139 MAX44CP005 - TAPPING
POINT ......................................................................... 962
INDICATOR ............................................................ 962
INDICATOR ............................................................ 963
INDICATOR ............................................................ 963
1.143 MKA10CT001 - TEMP.
TRANSMITTER................................................................ 964
en HTGD 693 000 V0140 A

889
WP4140
1.144 MKA10CT002 - TEMP.

TRANSMITTER ............................................................... 964
1.145 MKA10CT003 - TEMP.
TRANSMITTER ............................................................... 965
1.146 MKA10CT004 - TEMP.
TRANSMITTER ............................................................... 965
1.147 MKA10CT005 - TEMP.
TRANSMITTER ............................................................... 966
1.148 MKA10CT006 - TEMP.
TRANSMITTER ............................................................... 966
1.149 MKA10CT007 - TEMP.
TRANSMITTER ............................................................... 967
1.150 MKA10CT008 - TEMP.
TRANSMITTER ............................................................... 967
1.151 MKA10CT009 - TEMP.
TRANSMITTER ............................................................... 968
1.152 MKA13CL011 - Level
measurement......................................................................
968
1.153 MKA13CT011 - TEMP.
TRANSMITTER ............................................................... 969
1.154 MKA13CT016 - TEMP.
TRANSMITTER ............................................................... 969
1.155 MKA13CT021 - TEMP.
TRANSMITTER ............................................................... 970
1.156 MKA13CT026 - TEMP.
TRANSMITTER ............................................................... 970
1.157 MKA13CT031 - TEMP.
TRANSMITTER ............................................................... 971
1.158 MKD10CT001 - TEMP.
GAUGE............................................................................
971
1.159 MKD10CY021 - SHAFT VIB
PROBE .................................................................... 972
PROBE .................................................................... 972
1.161 MKD11CT001 - TEMP.
TRANSMITTER ............................................................... 973
1.162 MKD20CP001 - TAPPING
POINT......................................................................... 973
1.163 MKD20CT001 - TEMP.
GAUGE............................................................................
974
PROBE .................................................................... 974
PROBE .................................................................... 975
1.166 MKD21CP001 - TAPPING
POINT......................................................................... 975
1.167 MKD21CT001 - TEMP.
TRANSMITTER ............................................................... 976
890 HTGD 693 000 V0140 A
en
Documents
ALLMETRA_TC- - Allmetra Thermo Element

TC ...................................................................... 977
BAUMER_IFRM12P17- - Inductive Sensor
IFRM12P17405909............................................... 986
HTGD691697V0003- - Proportional Directional Valve with
Feedback ...................................... 987
HTGD691723V0001B - Power
Amplifier .........................................................................
........ 1019
HTGD691732V0001C - Inductive Displacement
Transducer .................................................. 1041
HTGD691735V0003C - Pressure Transmitter Type
3051C .................................................... 1051
HTGD691735V0004B - Pressure Transmitter Type 3051T L
H ............................................ 1081
HTGD691765V0002A - Level Sensor Control unit type
XT42SI ............................................. 1119
HTGD691767V0004- - Ferrostat
Sensor ............................................................................
..... 1143
HTGD691768V0001B - Inductive Angle
Transducer............................................................... 1148
HTGD691785V0001- - Level
Indicator .........................................................................
........... 1158
HTGD691805V0002A - Linear
Transducer ........................................................................
..... 1162
HTGD691830V0001A - Dial
Thermometer........................................................................
...... 1172
HTGD691842V0003B - Proximity
Sensor ............................................................................
... 1184
HTGD691842V0005- - Proximity
Sensor.............................................................................
.... 1208
HTGD691855V0001A - Proximity
Sensor ............................................................................
... 1222
HTGD691888V0001B - Digital Valve Controller Type
DVC2000 ............................................ 1242
HTGD691893V0001- - Limit
Switch.............................................................................
............ 1290
HTGD691894V0001- - Limit switch M22-
K10.......................................................................... 1296
HTGD691895V0001- - Switch disconnector P1-32EASVBHI
11............................................. 1300
PEPPERL_FUCHS_NCN4_12GM40- - Limit Switch Pepperl Fuchs NCN4-12GM40.............
1304
ROSEMOUNT_00813_4728- - Rosemount 644 Smart Temperature
Transmitter .................. 1305
WIKA_IN00-05- - Elastic Element Pressure Gauges Selection Installation Handling and
Operation..........................................................................
.............................................. 1329
WIKA_PM02-06- - Bourdon Tube Pressure Gauge Model
213.40.......................................... 1333
WIKA_PM02-10- - Bourdon Tube Pressure Gauges Model
232.34233.34 ............................. 1335
WIKA_TM53-01- - Bimetal Thermometers Model
53............................................................... 1337
WIKA_TM55-01- - Bimetal Thermometers Model
55............................................................... 1341
en HTGD 693 000 V0140 A

891
-
892 HTGD 693 000 V0140 A en

1 INSTRUMENT LIST
1.1 MAA10CF001 - PLUG

Short Description: F PISTON STEAM HPT
Device Type: PLUG
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
P Design [Unit P]: 0.10 [bar g]
T Design [Unit T]: 200.00 [Cel]
1.2 MAA10CP001 - PRESSURE TRANSMITTER

Short Description: P UPSTR HPT BLADING
Device Type: PRESSURE TRANSMITTER
Model No.: 3051CG4A2B21AB4Q4KV1
HTGD691735V0003.pdf
Manufacturer: Rosemount
Junct Box ID:
Ex Protect: NO
Instr Rack ID: MAA10GZ001
Medium: STEAM
en HTGD 693 000 V0140 A 893

1.3 MAA10CP002 - ROOT VALVE

Short Description: P UPSTR HPT BLADING
Device Type: ROOT VALVE
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: MAA10GZ001
Medium: STEAM
1.4 MAA10CP031 - TAPPING POINT

Short Description: P HP TURBINE EXHAUST
Device Type: TAPPING POINT
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: STEAM
894 HTGD 693 000 V0140 A en

1.5 MAA10CT005A - 1xTC. TEMP TRANSM

Short Description: T HPT STRESS CALC
Device Type: 1xTC. TEMP TRANSM
Model No.: TYPE N 644R
ALLMETRA_TC.pdf
ROSEMOUNT_00813_4728.pdf
Manufacturer: Allmetra & Rosemount
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
1.6 MAA10CT005B - 1xTC. TEMP TRANSM

ALLMETRA_TC.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
en HTGD 693 000 V0140 A 895

1.7 MAA10CT005C - 1xTC. TEMP TRANSM

ALLMETRA_TC.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
1.8 MAA10CT010 - 3xTC. TEMP TRANSM

Short Description: T VENT PROT HP TURB
ALLMETRA_TC.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
P Design [Unit P]: 0.00 [-]
T Design [Unit T]: 0.00 [-]
896 HTGD 693 000 V0140 A en

1.9 MAA10CT026 - THERMOWELL

Short Description: T PISTON STEAM HPT
Device Type: THERMOWELL
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM

Short Description: T HP TURBINE EXHAUST
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
en HTGD 693 000 V0140 A 897


Short Description: T HP TURBINE EXHAUST
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
1.12 MAA12CG001 - POSITION TRANSMITTER

Short Description: POS MAIN STOP VALVE
Device Type: POSITION TRANSMITTER
Model No.: BTL5-E17-M0125-K-SR32
HTGD691805V0002.pdf
Manufacturer: BALLUFF
Junct Box ID: MAA12GD001
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
898 HTGD 693 000 V0140 A en


Short Description: POS MAIN CTRL VALVE
Model No.: BTL5-E17-M0125-K-SR32
HTGD691805V0002.pdf
Manufacturer: BALLUFF
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -

Short Description: POS EHC MCV
Model No.: KFDG4V
HTGD691723V0001.pdf
HTGD691697V0003.pdf
Manufacturer: Vickers
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
en HTGD 693 000 V0140 A 899

1.15 MAC10CG101 - LIMIT SWITCH

Short Description: POS VACUUM BREAKER
Device Type: LIMIT SWITCH
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Short Description: POS VACUUM BREAKER
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
900 HTGD 693 000 V0140 A en

1.17 MAC10CP001 - PRESSURE TRANSMITTER

Short Description: P UPSTR LP BLADING
Model No.: 3051CG4A22A1AB4Q4KV1
HTGD691735V0003.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: MAC10GZ001
Medium: STEAM
1.18 MAC10CP002 - ROOT VALVE

Short Description: P UPSTR LP BLADING
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID:
Medium: STEAM
en HTGD 693 000 V0140 A 901

1.19 MAC10CP006 - ROOT VALVE

Short Description: P DNSTR LPS-CV
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID:
Medium: STEAM

Short Description: P LPT EXHAUST
Model No.: 3051TA1A2C21AQ4KV1
HTGD691735V0004.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
P Design [Unit P]: 0.10 [bar a]
902 HTGD 693 000 V0140 A en


HTGD691735V0004.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM

HTGD691735V0004.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
en HTGD 693 000 V0140 A 903

1.23 MAC10CP071 - TAPPING POINT

Short Description: P LPT EXHAUST BLW
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM

Short Description: P LPT EXHAUST BLW
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
904 HTGD 693 000 V0140 A en


Short Description: P LPT EXHAUST ABV
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM

Short Description: P LPT EXHAUST ABV
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
en HTGD 693 000 V0140 A 905

1.27 MAC10CT010 - 3xTC. TEMP TRANSM

Short Description: T VENT PROT LP TURB
ALLMETRA_TC.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
P Design [Unit P]: 0.00 [-]
1.28 MAC10CT021 - 1xTC. TEMP TRANSM

Short Description: T UPSTR LP-BLADING
ALLMETRA_TC.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
906 HTGD 693 000 V0140 A en

1.29 MAC10CT081 - 1xTC TEMP TRANSM

Short Description: T LPT EXHAUST ABV
Device Type: 1xTC TEMP TRANSM
Model No.: TYPE N 644H
ALLMETRA_TC.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
P Design [Unit P]: 87.00 [mbara]
1.30 MAC10CT082 - TEMPERATURE INDICATOR

Short Description: T LPT EXHAUST ABV
Device Type: TEMPERATURE INDICATOR
Model No.: TFV100AI
HTGD691830V0001.pdf
Manufacturer: Rueger
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
P Design [Unit P]: 87.00 [mbara]
en HTGD 693 000 V0140 A 907

1.31 MAC10CY011 - DIFF EXP PROBE

Short Description: DIFF EXPANSION LPT
Device Type: DIFF EXP PROBE
Model No.: 330708-00-25-90-02-00
HTGD691842V0003.pdf
Manufacturer: BENTLY NEVADA
Junct Box ID: MAD50GD001
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
1.32 MAC10CY012 - DIFF EXP PROBE

Short Description: DIFF EXPANSION LPT
Device Type: DIFF EXP PROBE
Model No.: 330708-00-25-90-02-00
HTGD691842V0003.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
908 HTGD 693 000 V0140 A en

1.33 MAC31CG011 - POSITION TRANSMITTER

Short Description: POS LPS CTRL VALVE
Model No.: ID583-105-0-5
HTGD691768V0001.pdf
Manufacturer: TWK
Junct Box ID: MAC31GD001
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
1.34 MAC31CG031 - POSITION TRANSMITTER

Short Description: POS EHC LPS-CV
Model No.: KFDG4V
HTGD691723V0001.pdf
HTGD691697V0003.pdf
Manufacturer: Vickers
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
en HTGD 693 000 V0140 A 909


Short Description: POS LPS-SV
Model No.: IFRM 12P1568
BAUMER_IFRM12P17.pdf
Manufacturer: Baumer
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Short Description: POS LPS-SV
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
910 HTGD 693 000 V0140 A en


Short Description: POS LP HOOD WI V
Model No.: 3SE3 120-1E
HTGD691893V0001.pdf
Manufacturer: SIEMENS
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Short Description: POS LP HOOD WI V
Model No.: 3SE3 120-1E
HTGD691893V0001.pdf
Manufacturer: SIEMENS
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
en HTGD 693 000 V0140 A 911


Short Description: P LP HOOD WI
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: WATER
1.40 MAD20CS001 - SPEED PROBE

Short Description: SPEED PROBE
Device Type: SPEED PROBE
Model No.: FTG 1087.00AH-140
HTGD691767V0004.pdf
Manufacturer: Jaquet AG
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
912 HTGD 693 000 V0140 A en


HTGD691767V0004.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -

HTGD691767V0004.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
en HTGD 693 000 V0140 A 913

1.43 MAD20CY004 - DISPL TRANSDUCER

Short Description: ABS EXP TURBINE
Device Type: DISPL TRANSDUCER
Model No.: IW253/40-0.5-"T"
HTGD691732V0001.pdf
Manufacturer: TWK
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
1.44 MAD20CY011 - THRUST POS PROBE

Short Description: THRUST POSITION
Device Type: THRUST POS PROBE
Model No.: 330707-00-20-10-02-00
HTGD691842V0003.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
P Design [Unit P]: 0.00
T Design [Unit T]: 0.00
914 HTGD 693 000 V0140 A en

1.45 MAD20CY012 - THRUST POS PROBE

Short Description: THRUST POSITION
Device Type: THRUST POS PROBE
Model No.: 330707-00-20-10-02-00
HTGD691842V0003.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: -
P Design [Unit P]: 0.00
T Design [Unit T]: 0.00
1.46 MAD20CY021 - PROXPAC

Short Description: VIB SHAFT RELATIVE
Device Type: PROXPAC
Model No.: 330881-16-00-385-06-02
HTGD691842V0005.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
en HTGD 693 000 V0140 A 915


Model No.: 330881-16-00-385-06-02
HTGD691842V0005.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Short Description: KEY PHASOR
Model No.: 330881-16-00-200-06-02
HTGD691842V0005.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
916 HTGD 693 000 V0140 A en

1.49 MAD21CT001 - 2xTC. TEMP TRANSM

Short Description: T METAL RADIAL BRG
ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL

ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL
en HTGD 693 000 V0140 A 917


Short Description: T METAL THRUST BRG
ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL

ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL
918 HTGD 693 000 V0140 A en


ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL

ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL
en HTGD 693 000 V0140 A 919

1.55 MAD50CY021 - SHAFT VIB PROBE

Device Type: SHAFT VIB PROBE
Model No.: 330102-00-18-90-02-00
HTGD691855V0001.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
1.56 MAD50CY022 - SHAFT VIB PROBE

Model No.: 330102-00-18-90-02-00
HTGD691855V0001.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
920 HTGD 693 000 V0140 A en


ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL

ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: METAL
en HTGD 693 000 V0140 A 921

1.59 MAK80CG005 - LIMIT SWITCH

Short Description: POS TRNGR PROT CAP
Model No.: NCN4-12GM40-Z0
PEPPERL_FUCHS_NCN4_12GM40.pdf
Manufacturer: Pepperl & Fuchs
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Short Description: POS TRNGR PROT CAP
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
922 HTGD 693 000 V0140 A en


Short Description: POS ENGAGED TRNGR
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Short Description: POS LCL PB TRNGR
Model No.: N22-K10
HTGD691894V0001.pdf
Manufacturer: MOELLER
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
en HTGD 693 000 V0140 A 923


Short Description: POS MAINT SWITCH
Model No.: P1-32EA/SVB/HI 11
HTGD691895V0001.pdf
Manufacturer: MOELLER
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
1.64 MAK80EE211 - INDICATION TRNGR POS

Short Description: INDICATION TRNGR POS
Device Type:
Model No.: BRC73121
N.A.
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID: N.A.
Medium:
P Design [Unit P]:
T Design [Unit T]:
924 HTGD 693 000 V0140 A en

List
1.65 MAV02CL001 - LEVEL SENSOR

Short Description: L LOIL TANK
Device Type: LEVEL SENSOR
Model No.: AEV1,5-VK12-L1000-SVK-XT42SI
HTGD691765V0002.pdf
Manufacturer: Kuebler AG
Junct Box ID: MAV02GD001
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.66 MAV02CL001A - LEVEL INDICATOR

Short Description: L LUBE OIL TANK
Device Type: LEVEL INDICATOR
Model No.: A96-K
HTGD691785V0001.pdf
Manufacturer: Kuebler AG
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 925

1.67 MAV02CP001 - TAPPING POINT

Short Description: P LOIL TANK
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.68 MAV02CT001 - TEMPERATURE GAUGE

Short Description: T LOIL TANK
Device Type: TEMPERATURE GAUGE
Model No.: A5500, NG100, DATA SH. TM55.01
WIKA_TM55-01.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
926 HTGD 693 000 V0140 A en

1.69 MAV21CP011 - PRESSURE GAUGE

Short Description: P DNSTR MNOPP
Device Type: PRESSURE GAUGE
Model No.: 232.34 NG 4 1/2"
WIKA_PM02-10.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.70 MAV21CP021 - PRESSURE INDICATOR

Short Description: P DNSTR AUXOPP
Device Type: PRESSURE INDICATOR
Model No.: N.A.
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 927


Short Description: P DNSTR EMEROPP
Model No.: N.A.
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Short Description: T LOIL UPSTR COOLER
ALLMETRA_TC.pdf
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
928 HTGD 693 000 V0140 A en


Short Description: T LOIL DNSTR COOLER
ALLMETRA_TC.pdf
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.74 MAV23CP001 - DIFF. PRESS. ALARM

Short Description: P DIFF LOIL FLTR
Device Type: DIFF. PRESS. ALARM
Model No.:
Manufacturer: HYDAC
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 929

1.75 MAV23CP001A - DIFF. PRESS. INDIC.

Short Description: P DIFF LOIL FLTR
Device Type: DIFF. PRESS. INDIC.
Model No.:
Manufacturer: HYDAC
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.76 MAV40CP002 - ROOT VALVE

Short Description: P LOIL SPLY BRG
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
930 HTGD 693 000 V0140 A en

1.77 MAV40CP003 - PRESSURE TRANSMITTER

Short Description: P LOIL HEADER
Model No.: 3051TG2A2B21AB4Q4KV1KS1BZS
HTGD691735V0004.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

HTGD691735V0004.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 931


HTGD691735V0004.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
932 HTGD 693 000 V0140 A en


Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 933


Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
934 HTGD 693 000 V0140 A en


Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Short Description: P TEST CONNECTION
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 935


Short Description: T LOIL HEADER
Model No.: TM55.01. TYPE R5502, NG100
WIKA_TM55-01.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.88 MAV40CT002 - TEMP. TRANSMITTER

Short Description: T LOIL HEADER
Device Type: TEMP. TRANSMITTER
ALLMETRA_TC.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
936 HTGD 693 000 V0140 A en


Short Description: P DNSTR JOP
Model No.: 232.34 NG 4 1/2"
WIKA_PM02-10.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Short Description: P JACKING OIL
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 937


Short Description: P JACKING OIL
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Short Description: T BRG LOIL RTN
Model No.: TM53.02
WIKA_TM53-01.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
938 HTGD 693 000 V0140 A en


Model No.: PT100, 644H
ALLMETRA_TC.pdf
Manufacturer: ALLMETRA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Model No.: TM54.02
WIKA_TM53-01.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 939


Model No.: PT100, 644H
ALLMETRA_TC.pdf
Manufacturer: ALLMETRA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.96 MAV91CE001 - E OIL CENTRIF

Short Description: E OIL CENTRIF
Device Type:
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
940 HTGD 693 000 V0140 A en


Device Type:
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Device Type:
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 941

1.99 MAV91CF001 - F UPSTR OIL CNTFG

Short Description: F UPSTR OIL CNTFG
Device Type:
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.100 MAV91CL001 - L CNTFG WASTE TANK

Short Description: L CNTFG WASTE TANK
Device Type:
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
942 HTGD 693 000 V0140 A en

1.101 MAV91CT002 - T OIL HEATER

Short Description: T OIL HEATER
Device Type:
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.102 MAV91CT006 - T UPSTR OIL CNTFG

Short Description: T UPSTR OIL CNTFG
Device Type:
Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 943

1.103 MAW10CG011 - POSITION TRANSMITTER

Short Description: POS GLS SEG ADM V
Model No.: DVC2000
HTGD691888V0001.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.104 MAW10CP001 - PRESSURE INDICATOR

Short Description: P GLS SEALING SYS
Model No.: 232.34 NG 4 1/2"
WIKA_PM02-10.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
944 HTGD 693 000 V0140 A en

1.105 MAW15CG061 - POSITION TRANSMITTER

Short Description: POS GLS SEG WINJ CV
Model No.: DVC2000
HTGD691888V0001.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.106 MAW15CP001 - PRESSURE TRANSMITTER

Short Description: P GLDST SEALING SYS
Model No.: 3051CG3A22A1AB4M5Q4KV1
HTGD691735V0003.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: MAW15GZ001
Medium: STEAM
en HTGD 693 000 V0140 A 945

1.107 MAW15CP001A - PRESSURE GAUGE

Model No.:
Manufacturer:
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: STEAM
1.108 MAW15CP002 - TAPPING POINT

Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: STEAM
946 HTGD 693 000 V0140 A en


Short Description: P WINJ GLS SEG SYS
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: WATER
1.110 MAW15CP011 - DIFF.PRESS.GAUGE

Short Description: DP AT GLNDST WTR INJ STR
Device Type: DIFF.PRESS.GAUGE
Model No.: WFDP45
N.A.
Manufacturer: GEFA
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: WATER
en HTGD 693 000 V0140 A 947

1.111 MAW15CT001 - 2xTC. TEMP TRANSM

Short Description: T GLS SEALING SYS
ALLMETRA_TC.pdf
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
1.112 MAW15CT002 - TEMPERATURE GAUGE

Model No.: TFV100AI
HTGD691830V0001.pdf
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
948 HTGD 693 000 V0140 A en

1.113 MAW15CT003 - TEMPERATURE GAUGE

Model No.: TFV100AI
HTGD691830V0001.pdf
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
1.114 MAW30CL001 - LIQUID LEVEL GAUGE

Short Description: L GLDST SUCT COND
Device Type: LIQUID LEVEL GAUGE
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: CONDENSATE
en HTGD 693 000 V0140 A 949

1.115 MAW30CP001 - ROOT VALVE

Short Description: P GLDST SUCTION SYS
Model No.: 3/4" NPT-F
N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: STEAM
1.116 MAW30CP002 - ROOT VALVE

Model No.: 3/4" NPT-F
N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: STEAM
950 HTGD 693 000 V0140 A en


Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: STEAM
1.118 MAW30CT002 - THERMOWELL

Short Description: T GLS SUCTION SYSTEM
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: STEAM
en HTGD 693 000 V0140 A 951


Short Description: T CW UPSTR GSSC
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: WATER
P Design [Unit P]:
T Design [Unit T]:

Short Description: T CW DNSTR GSSC
Model No.:
Manufacturer: N.A.
Junct Box ID:
Ex Protect:
Instr Rack ID:
Medium: WATER
P Design [Unit P]:
T Design [Unit T]:
952 HTGD 693 000 V0140 A en

1.121 MAX00EW011 - EMERG STOP SWITCH

Short Description: POS LCL STT PB TURB
Device Type: EMERG STOP SWITCH
Model No.: XS 535 616-SM
N.A.
Manufacturer: ABB CONTROL
Junct Box ID: MAX00EW001
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Short Description: POS LCL STT PB HYSU
N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
en HTGD 693 000 V0140 A 953


N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
954 HTGD 693 000 V0140 A en


N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium:
en HTGD 693 000 V0140 A 955

1.127 MAX11CP001 - PRESSURE GAUGE

Short Description: P HYDRAULIC PUMP
Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Short Description: P HYDRAULIC PUMP
Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
956 HTGD 693 000 V0140 A en

List
1.129 MAX11CP031 - PRESSURE TRANSMITTER

Short Description: P HYDR HEADER
HTGD691735V0004.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Short Description: P HYDR HEADER
Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 957

1.131 MAX13CP001 - DIFF. PRESS. ALARM

Short Description: P DIFF HYDR FILTER
Device Type: DIFF. PRESS. ALARM
Model No.:
Manufacturer: HYDAC
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.132 MAX13CP001A - DIFF. PRESS. INDIC.

Short Description: P DIFF HYDR FILTER
Device Type: DIFF. PRESS. INDIC.
Model No.:
Manufacturer: HYDAC
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
958 HTGD 693 000 V0140 A en

1.133 MAX15CP001 - PRESSURE INDICATOR

Short Description: P HYDR ACC
Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
1.134 MAX16CP002 - TAPPING POINT

Short Description: P HYDRAULIC HEADER
Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 959

1.135 MAX44CG001 - LIMIT SWITCH

Short Description: POS SEQUENCE VALVE
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Short Description: P SAFETY SYSTEM
HTGD691735V0004.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
960 HTGD 693 000 V0140 A en

List

HTGD691735V0004.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

HTGD691735V0004.pdf
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 961

1.139 MAX44CP005 - TAPPING POINT

Model No.: N.A.
Manufacturer: N.A.
Junct Box ID:
Ex Protect: NO
Instr Rack ID: N.A.
Medium:

Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
962 HTGD 693 000 V0140 A en


Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL

Model No.: 213.40 NG100
WIKA_IN00-05.pdf
WIKA_PM02-06.pdf
Manufacturer: WIKA
Junct Box ID: N.A.
Ex Protect: NO
Instr Rack ID: N.A.
Medium: OIL
en HTGD 693 000 V0140 A 963

1.143 MKA10CT001 - TEMP. TRANSMITTER

Short Description: T STATOR WINDING
Model No.:
Manufacturer: N.A.
Junct Box ID: MKA10GA002
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
964 HTGD 693 000 V0140 A en


Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 965


Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
966 HTGD 693 000 V0140 A en


Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 967


Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.152 MKA13CL011 - Level measurement

Short Description: IND LEAKAGE WTR GEN
Device Type: Level measurement
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
968 HTGD 693 000 V0140 A en


Short Description: T WRM A GEN OUTL DE
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Short Description: T COLD A GEN INL DE
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 969


Short Description: T WRM A GEN OUTL NDE
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Short Description: T COLD A GEN INL NDE
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
970 HTGD 693 000 V0140 A en


Short Description: T EXCITER
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.158 MKD10CT001 - TEMP. GAUGE

Short Description: T LOIL RTN
Device Type: TEMP. GAUGE
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 971

1.159 MKD10CY021 - SHAFT VIB PROBE

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
972 HTGD 693 000 V0140 A en

1.161 MKD11CT001 - TEMP. TRANSMITTER

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.162 MKD20CP001 - TAPPING POINT

Short Description: P LUBE OIL BRG
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 973

1.163 MKD20CT001 - TEMP. GAUGE

Short Description: T LOIL RTN
Device Type: TEMP. GAUGE
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
974 HTGD 693 000 V0140 A en


Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
1.166 MKD21CP001 - TAPPING POINT

Short Description: P LUBE OIL BRG
Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
en HTGD 693 000 V0140 A 975

1.167 MKD21CT001 - TEMP. TRANSMITTER

Model No.:
Manufacturer: N.A.
Ex Protect:
Instr Rack ID:
Medium:
P Design [Unit P]:
T Design [Unit T]:
976 HTGD 693 000 V0140 A en

2 DOCUMENTS
2.1 ALLMETRA_TC- (Page_1)
ALLMETRA_TC- - Allmetra Thermo Element TC
en HTGD 693 000 V0140 A 977

2.1.1 ALLMETRA_TC- (Page_2)
ALLMETRA_TC- - Allmetra Thermo Element TC_Page_2
978 HTGD 693 000 V0140 A en

List
en HTGD 693 000 V0140 A 979

980 HTGD 693 000 V0140 A en

List
en HTGD 693 000 V0140 A 981

982 HTGD 693 000 V0140 A en

List
en HTGD 693 000 V0140 A 983

984 HTGD 693 000 V0140 A en

List
en HTGD 693 000 V0140 A 985

2.2 BAUMER_IFRM12P17
BAUMER_IFRM12P17- - Inductive Sensor IFRM12P17405909
986 HTGD 693 000 V0140 A en

MA -
Instrumentation List
2.3 HTGD691697V0003- (Page_01)

HTGD691697V0003- - Proportional Directional Valve with Feedback
en HTGD 693 000 V0140 A

987
2.3.1 HTGD691697V0003- (Page_02)
HTGD691697V0003- - Proportional Directional Valve with Feedback_Page_02
988 HTGD 693 000 V0140 A

en
List
2.3.2 HTGD691697V0003- (Page_03)
en HTGD 693 000 V0140 A

989
2.3.3 HTGD691697V0003- (Page_04)
990 HTGD 693 000 V0140 A

en
List
2.3.4 HTGD691697V0003- (Page_05)
en HTGD 693 000 V0140 A

991
2.3.5 HTGD691697V0003- (Page_06)
992 HTGD 693 000 V0140 A

en
List
2.3.6 HTGD691697V0003- (Page_07)
en HTGD 693 000 V0140 A

993
2.3.7 HTGD691697V0003- (Page_08)
994 HTGD 693 000 V0140 A

en
List
2.3.8 HTGD691697V0003- (Page_09)
en HTGD 693 000 V0140 A

995
2.3.9 HTGD691697V0003- (Page_10)
HTGD691697V0003- - Proportional Directional Valve with Feedback0
996 HTGD 693 000 V0140 A en

MA -
2.3.10 HTGD691697V0003- (Page_11)
en HTGD 693 000 V0140 A

997
2.3.11 HTGD691697V0003- (Page_12)
998 HTGD 693 000 V0140 A en

MA -
2.3.12 HTGD691697V0003- (Page_13)
en HTGD 693 000 V0140 A

999
2.3.13 HTGD691697V0003- (Page_14)
1000 HTGD 693 000 V0140 A en

MA -
2.3.14 HTGD691697V0003- (Page_15)
en HTGD 693 000 V0140 A

1001
2.3.15 HTGD691697V0003- (Page_16)
1002 HTGD 693 000 V0140 A en

MA -
2.3.16 HTGD691697V0003- (Page_17)
en HTGD 693 000 V0140 A

1003
2.3.17 HTGD691697V0003- (Page_18)
1004 HTGD 693 000 V0140 A en

MA -
2.3.18 HTGD691697V0003- (Page_19)
en HTGD 693 000 V0140 A

1005
2.3.19 HTGD691697V0003- (Page_20)
1006 HTGD 693 000 V0140 A

en
List
2.3.20 HTGD691697V0003- (Page_21)
en HTGD 693 000 V0140 A

1007
2.3.21 HTGD691697V0003- (Page_22)
1008 HTGD 693 000 V0140 A

en
List
2.3.22 HTGD691697V0003- (Page_23)
en HTGD 693 000 V0140 A

1009
2.3.23 HTGD691697V0003- (Page_24)
1010 HTGD 693 000 V0140 A

en
List
2.3.24 HTGD691697V0003- (Page_25)
en HTGD 693 000 V0140 A

1011
2.3.25 HTGD691697V0003- (Page_26)
1012 HTGD 693 000 V0140 A

en
List
2.3.26 HTGD691697V0003- (Page_27)
en HTGD 693 000 V0140 A

1013
2.3.27 HTGD691697V0003- (Page_28)
1014 HTGD 693 000 V0140 A

en
List
2.3.28 HTGD691697V0003- (Page_29)
en HTGD 693 000 V0140 A

1015
2.3.29 HTGD691697V0003- (Page_30)
1016 HTGD 693 000 V0140 A

en
List
2.3.30 HTGD691697V0003- (Page_31)
en HTGD 693 000 V0140 A

1017
2.3.31 HTGD691697V0003- (Page_32)
1018 HTGD 693 000 V0140 A

en
2.4 HTGD691723V0001B (Page_01)

HTGD691723V0001B - Power Amplifier
en HTGD 693 000 V0140 A 1019

2.4.1 HTGD691723V0001B (Page_02)
HTGD691723V0001B - Power Amplifier_Page_02
1020 HTGD 693 000 V0140 A en

2.4.2 HTGD691723V0001B (Page_03)
en HTGD 693 000 V0140 A 1021

2.4.3 HTGD691723V0001B (Page_04)
1022 HTGD 693 000 V0140 A en

2.4.4 HTGD691723V0001B (Page_05)
en HTGD 693 000 V0140 A 1023

2.4.5 HTGD691723V0001B (Page_06)
1024 HTGD 693 000 V0140 A en

2.4.6 HTGD691723V0001B (Page_07)
en HTGD 693 000 V0140 A 1025

2.4.7 HTGD691723V0001B (Page_08)
1026 HTGD 693 000 V0140 A en

2.4.8 HTGD691723V0001B (Page_09)
en HTGD 693 000 V0140 A 1027

2.4.9 HTGD691723V0001B (Page_10)
HTGD691723V0001B - Power Amplifier0
1028 HTGD 693 000 V0140 A en

2.4.10 HTGD691723V0001B (Page_11)
en HTGD 693 000 V0140 A 1029

2.4.11 HTGD691723V0001B (Page_12)
1030 HTGD 693 000 V0140 A en

2.4.12 HTGD691723V0001B (Page_13)
en HTGD 693 000 V0140 A 1031

2.4.13 HTGD691723V0001B (Page_14)
1032 HTGD 693 000 V0140 A en

2.4.14 HTGD691723V0001B (Page_15)
en HTGD 693 000 V0140 A 1033

2.4.15 HTGD691723V0001B (Page_16)
1034 HTGD 693 000 V0140 A en

2.4.16 HTGD691723V0001B (Page_17)
en HTGD 693 000 V0140 A 1035

2.4.17 HTGD691723V0001B (Page_18)
1036 HTGD 693 000 V0140 A en

2.4.18 HTGD691723V0001B (Page_19)
en HTGD 693 000 V0140 A 1037

2.4.19 HTGD691723V0001B (Page_20)
1038 HTGD 693 000 V0140 A en

2.4.20 HTGD691723V0001B (Page_21)
en HTGD 693 000 V0140 A 1039

2.4.21 HTGD691723V0001B (Page_22)
1040 HTGD 693 000 V0140 A en

List
2.5 HTGD691732V0001C (Page_01)

HTGD691732V0001C - Inductive Displacement Transducer
en HTGD 693 000 V0140 A

1041
2.5.1 HTGD691732V0001C (Page_02)
HTGD691732V0001C - Inductive Displacement Transducer_Page_02
1042 HTGD 693 000 V0140 A en

List
2.5.2 HTGD691732V0001C (Page_03)
en HTGD 693 000 V0140 A 1043

2.5.3 HTGD691732V0001C (Page_04)
1044 HTGD 693 000 V0140 A en

List
2.5.4 HTGD691732V0001C (Page_05)
en HTGD 693 000 V0140 A 1045

2.5.5 HTGD691732V0001C (Page_06)
1046 HTGD 693 000 V0140 A en

List
2.5.6 HTGD691732V0001C (Page_07)
en HTGD 693 000 V0140 A 1047

2.5.7 HTGD691732V0001C (Page_08)
1048 HTGD 693 000 V0140 A en

List
2.5.8 HTGD691732V0001C (Page_09)
en HTGD 693 000 V0140 A 1049

2.5.9 HTGD691732V0001C (Page_10)
HTGD691732V0001C - Inductive Displacement Transducer0
1050 HTGD 693 000 V0140 A en

List
2.6 HTGD691735V0003C (Page_01)

HTGD691735V0003C - Pressure Transmitter Type 3051C
en HTGD 693 000 V0140 A 1051

2.6.1 HTGD691735V0003C (Page_02)
HTGD691735V0003C - Pressure Transmitter Type 3051C_Page_02
1052 HTGD 693 000 V0140 A en

2.6.2 HTGD691735V0003C (Page_03)
en HTGD 693 000 V0140 A 1053

2.6.3 HTGD691735V0003C (Page_04)
1054 HTGD 693 000 V0140 A en

2.6.4 HTGD691735V0003C (Page_05)
en HTGD 693 000 V0140 A 1055

2.6.5 HTGD691735V0003C (Page_06)
1056 HTGD 693 000 V0140 A en

2.6.6 HTGD691735V0003C (Page_07)
en HTGD 693 000 V0140 A 1057

2.6.7 HTGD691735V0003C (Page_08)
1058 HTGD 693 000 V0140 A en

2.6.8 HTGD691735V0003C (Page_09)
en HTGD 693 000 V0140 A 1059

2.6.9 HTGD691735V0003C (Page_10)
HTGD691735V0003C - Pressure Transmitter Type 3051C0
1060 HTGD 693 000 V0140 A en

List
2.6.10 HTGD691735V0003C (Page_11)
en HTGD 693 000 V0140 A

1061
2.6.11 HTGD691735V0003C (Page_12)
1062 HTGD 693 000 V0140 A en

List
2.6.12 HTGD691735V0003C (Page_13)
en HTGD 693 000 V0140 A

1063
2.6.13 HTGD691735V0003C (Page_14)
1064 HTGD 693 000 V0140 A en

List
2.6.14 HTGD691735V0003C (Page_15)
en HTGD 693 000 V0140 A

1065
2.6.15 HTGD691735V0003C (Page_16)
1066 HTGD 693 000 V0140 A en

List
2.6.16 HTGD691735V0003C (Page_17)
en HTGD 693 000 V0140 A

1067
2.6.17 HTGD691735V0003C (Page_18)
1068 HTGD 693 000 V0140 A en

List
2.6.18 HTGD691735V0003C (Page_19)
en HTGD 693 000 V0140 A

1069
2.6.19 HTGD691735V0003C (Page_20)
1070 HTGD 693 000 V0140 A en

List
2.6.20 HTGD691735V0003C (Page_21)
en HTGD 693 000 V0140 A 1071

2.6.21 HTGD691735V0003C (Page_22)
1072 HTGD 693 000 V0140 A en

List
2.6.22 HTGD691735V0003C (Page_23)
en HTGD 693 000 V0140 A 1073

2.6.23 HTGD691735V0003C (Page_24)
1074 HTGD 693 000 V0140 A en

List
2.6.24 HTGD691735V0003C (Page_25)
en HTGD 693 000 V0140 A 1075

2.6.25 HTGD691735V0003C (Page_26)
1076 HTGD 693 000 V0140 A en

List
2.6.26 HTGD691735V0003C (Page_27)
en HTGD 693 000 V0140 A 1077

2.6.27 HTGD691735V0003C (Page_28)
1078 HTGD 693 000 V0140 A en

List
2.6.28 HTGD691735V0003C (Page_29)
en HTGD 693 000 V0140 A 1079

2.6.29 HTGD691735V0003C (Page_30)
1080 HTGD 693 000 V0140 A en

List
2.7 HTGD691735V0004B (Page_01)

HTGD691735V0004B - Pressure Transmitter Type 3051T L H
en HTGD 693 000 V0140 A

1081
2.7.1 HTGD691735V0004B (Page_02)
HTGD691735V0004B - Pressure Transmitter Type 3051T L H_Page_02
1082 HTGD 693 000 V0140 A en

2.7.2 HTGD691735V0004B (Page_03)
en HTGD 693 000 V0140 A 1083

2.7.3 HTGD691735V0004B (Page_04)
1084 HTGD 693 000 V0140 A en

2.7.4 HTGD691735V0004B (Page_05)
en HTGD 693 000 V0140 A 1085

2.7.5 HTGD691735V0004B (Page_06)
1086 HTGD 693 000 V0140 A en

2.7.6 HTGD691735V0004B (Page_07)
en HTGD 693 000 V0140 A 1087

2.7.7 HTGD691735V0004B (Page_08)
1088 HTGD 693 000 V0140 A en

2.7.8 HTGD691735V0004B (Page_09)
en HTGD 693 000 V0140 A 1089

2.7.9 HTGD691735V0004B (Page_10)
HTGD691735V0004B - Pressure Transmitter Type 3051T L H0
1090 HTGD 693 000 V0140 A en

List
2.7.10 HTGD691735V0004B (Page_11)
en HTGD 693 000 V0140 A 1091

2.7.11 HTGD691735V0004B (Page_12)
1092 HTGD 693 000 V0140 A en

List
2.7.12 HTGD691735V0004B (Page_13)
en HTGD 693 000 V0140 A 1093

2.7.13 HTGD691735V0004B (Page_14)
1094 HTGD 693 000 V0140 A en

List
2.7.14 HTGD691735V0004B (Page_15)
en HTGD 693 000 V0140 A 1095

2.7.15 HTGD691735V0004B (Page_16)
1096 HTGD 693 000 V0140 A en

List
2.7.16 HTGD691735V0004B (Page_17)
en HTGD 693 000 V0140 A 1097

2.7.17 HTGD691735V0004B (Page_18)
1098 HTGD 693 000 V0140 A en

List
2.7.18 HTGD691735V0004B (Page_19)
en HTGD 693 000 V0140 A 1099

2.7.19 HTGD691735V0004B (Page_20)
1100 HTGD 693 000 V0140 A en

List
2.7.20 HTGD691735V0004B (Page_21)
en HTGD 693 000 V0140 A 1101

2.7.21 HTGD691735V0004B (Page_22)
1102 HTGD 693 000 V0140 A en

List
2.7.22 HTGD691735V0004B (Page_23)
en HTGD 693 000 V0140 A 1103

2.7.23 HTGD691735V0004B (Page_24)
1104 HTGD 693 000 V0140 A en

List
2.7.24 HTGD691735V0004B (Page_25)
en HTGD 693 000 V0140 A 1105

2.7.25 HTGD691735V0004B (Page_26)
1106 HTGD 693 000 V0140 A en

List
2.7.26 HTGD691735V0004B (Page_27)
en HTGD 693 000 V0140 A 1107

2.7.27 HTGD691735V0004B (Page_28)
1108 HTGD 693 000 V0140 A en

List
2.7.28 HTGD691735V0004B (Page_29)
en HTGD 693 000 V0140 A 1109

2.7.29 HTGD691735V0004B (Page_30)
1110 HTGD 693 000 V0140 A en

List
2.7.30 HTGD691735V0004B (Page_31)
en HTGD 693 000 V0140 A 1111

2.7.31 HTGD691735V0004B (Page_32)
1112 HTGD 693 000 V0140 A en

List
2.7.32 HTGD691735V0004B (Page_33)
en HTGD 693 000 V0140 A 1113

2.7.33 HTGD691735V0004B (Page_34)
1114 HTGD 693 000 V0140 A en

List
2.7.34 HTGD691735V0004B (Page_35)
en HTGD 693 000 V0140 A 1115

2.7.35 HTGD691735V0004B (Page_36)
1116 HTGD 693 000 V0140 A en

List
2.7.36 HTGD691735V0004B (Page_37)
en HTGD 693 000 V0140 A 1117

2.7.37 HTGD691735V0004B (Page_38)
1118 HTGD 693 000 V0140 A en

MA -
2.8 HTGD691765V0002A (Page_01)

HTGD691765V0002A - Level Sensor Control unit type XT42SI
en HTGD 693 000 V0140 A

1119
2.8.1 HTGD691765V0002A (Page_02)
HTGD691765V0002A - Level Sensor Control unit type XT42SI_Page_02
1120 HTGD 693 000 V0140 A en

List
2.8.2 HTGD691765V0002A (Page_03)
en HTGD 693 000 V0140 A 1121

2.8.3 HTGD691765V0002A (Page_04)
1122 HTGD 693 000 V0140 A en

List
2.8.4 HTGD691765V0002A (Page_05)
en HTGD 693 000 V0140 A 1123

2.8.5 HTGD691765V0002A (Page_06)
1124 HTGD 693 000 V0140 A en

List
2.8.6 HTGD691765V0002A (Page_07)
en HTGD 693 000 V0140 A 1125

2.8.7 HTGD691765V0002A (Page_08)
1126 HTGD 693 000 V0140 A en

List
2.8.8 HTGD691765V0002A (Page_09)
en HTGD 693 000 V0140 A 1127

2.8.9 HTGD691765V0002A (Page_10)
HTGD691765V0002A - Level Sensor Control unit type XT42SI0
1128 HTGD 693 000 V0140 A en

List
2.8.10 HTGD691765V0002A (Page_11)
en HTGD 693 000 V0140 A

1129
2.8.11 HTGD691765V0002A (Page_12)
1130 HTGD 693 000 V0140 A en

List
2.8.12 HTGD691765V0002A (Page_13)
en HTGD 693 000 V0140 A

1131
2.8.13 HTGD691765V0002A (Page_14)
1132 HTGD 693 000 V0140 A en

List
2.8.14 HTGD691765V0002A (Page_15)
en HTGD 693 000 V0140 A

1133
2.8.15 HTGD691765V0002A (Page_16)
1134 HTGD 693 000 V0140 A en

List
2.8.16 HTGD691765V0002A (Page_17)
en HTGD 693 000 V0140 A

1135
2.8.17 HTGD691765V0002A (Page_18)
1136 HTGD 693 000 V0140 A en

List
2.8.18 HTGD691765V0002A (Page_19)
en HTGD 693 000 V0140 A

1137
2.8.19 HTGD691765V0002A (Page_20)
1138 HTGD 693 000 V0140 A en

List
2.8.20 HTGD691765V0002A (Page_21)
en HTGD 693 000 V0140 A

1139
2.8.21 HTGD691765V0002A (Page_22)
1140 HTGD 693 000 V0140 A en

List
2.8.22 HTGD691765V0002A (Page_23)
en HTGD 693 000 V0140 A

1141
2.8.23 HTGD691765V0002A (Page_24)
1142 HTGD 693 000 V0140 A en

2.9 HTGD691767V0004- (Page_1)

HTGD691767V0004- - Ferrostat Sensor
en HTGD 693 000 V0140 A 1143

2.9.1 HTGD691767V0004- (Page_2)
HTGD691767V0004- - Ferrostat Sensor_Page_2
1144 HTGD 693 000 V0140 A en

2.9.2 HTGD691767V0004- (Page_3)
en HTGD 693 000 V0140 A 1145

2.9.3 HTGD691767V0004- (Page_4)
1146 HTGD 693 000 V0140 A en

2.9.4 HTGD691767V0004- (Page_5)
en HTGD 693 000 V0140 A 1147

2.10 HTGD691768V0001B (Page_01)

HTGD691768V0001B - Inductive Angle Transducer
1148 HTGD 693 000 V0140 A en

List
2.10.1 HTGD691768V0001B (Page_02)
HTGD691768V0001B - Inductive Angle Transducer_Page_02
en HTGD 693 000 V0140 A 1149

2.10.2 HTGD691768V0001B (Page_03)
1150 HTGD 693 000 V0140 A en

List
2.10.3 HTGD691768V0001B (Page_04)
en HTGD 693 000 V0140 A 1151

2.10.4 HTGD691768V0001B (Page_05)
1152 HTGD 693 000 V0140 A en

List
2.10.5 HTGD691768V0001B (Page_06)
en HTGD 693 000 V0140 A 1153

2.10.6 HTGD691768V0001B (Page_07)
1154 HTGD 693 000 V0140 A en

List
2.10.7 HTGD691768V0001B (Page_08)
en HTGD 693 000 V0140 A 1155

2.10.8 HTGD691768V0001B (Page_09)
1156 HTGD 693 000 V0140 A en

2.10.9 HTGD691768V0001B (Page_10)
HTGD691768V0001B - Inductive Angle Transducer0
en HTGD 693 000 V0140 A 1157

2.11 HTGD691785V0001- (Page_1)

HTGD691785V0001- - Level Indicator
1158 HTGD 693 000 V0140 A en

2.11.1 HTGD691785V0001- (Page_2)
HTGD691785V0001- - Level Indicator_Page_2
en HTGD 693 000 V0140 A 1159

2.11.2 HTGD691785V0001- (Page_3)
1160 HTGD 693 000 V0140 A en

2.11.3 HTGD691785V0001- (Page_4)
en HTGD 693 000 V0140 A 1161

2.12 HTGD691805V0002A (Page_01)

HTGD691805V0002A - Linear Transducer
1162 HTGD 693 000 V0140 A en

2.12.1 HTGD691805V0002A (Page_02)
HTGD691805V0002A - Linear Transducer_Page_02
en HTGD 693 000 V0140 A 1163

2.12.2 HTGD691805V0002A (Page_03)
1164 HTGD 693 000 V0140 A en

2.12.3 HTGD691805V0002A (Page_04)
en HTGD 693 000 V0140 A 1165

2.12.4 HTGD691805V0002A (Page_05)
1166 HTGD 693 000 V0140 A en

2.12.5 HTGD691805V0002A (Page_06)
en HTGD 693 000 V0140 A 1167

2.12.6 HTGD691805V0002A (Page_07)
1168 HTGD 693 000 V0140 A en

2.12.7 HTGD691805V0002A (Page_08)
en HTGD 693 000 V0140 A 1169

2.12.8 HTGD691805V0002A (Page_09)
1170 HTGD 693 000 V0140 A en

2.12.9 HTGD691805V0002A (Page_10)
HTGD691805V0002A - Linear Transducer0
en HTGD 693 000 V0140 A 1171

2.13 HTGD691830V0001A (Page_01)

HTGD691830V0001A - Dial Thermometer
1172 HTGD 693 000 V0140 A en

2.13.1 HTGD691830V0001A (Page_02)
HTGD691830V0001A - Dial Thermometer_Page_02
en HTGD 693 000 V0140 A 1173

2.13.2 HTGD691830V0001A (Page_03)
1174 HTGD 693 000 V0140 A en

2.13.3 HTGD691830V0001A (Page_04)
en HTGD 693 000 V0140 A 1175

2.13.4 HTGD691830V0001A (Page_05)
1176 HTGD 693 000 V0140 A en

2.13.5 HTGD691830V0001A (Page_06)
en HTGD 693 000 V0140 A 1177

2.13.6 HTGD691830V0001A (Page_07)
1178 HTGD 693 000 V0140 A en

2.13.7 HTGD691830V0001A (Page_08)
en HTGD 693 000 V0140 A 1179

2.13.8 HTGD691830V0001A (Page_09)
1180 HTGD 693 000 V0140 A en

2.13.9 HTGD691830V0001A (Page_10)
HTGD691830V0001A - Dial Thermometer0
en HTGD 693 000 V0140 A 1181

2.13.10 HTGD691830V0001A (Page_11)
1182 HTGD 693 000 V0140 A en

2.13.11 HTGD691830V0001A (Page_12)
en HTGD 693 000 V0140 A 1183

2.14 HTGD691842V0003B (Page_01)

HTGD691842V0003B - Proximity Sensor
1184 HTGD 693 000 V0140 A en

2.14.1 HTGD691842V0003B (Page_02)
HTGD691842V0003B - Proximity Sensor_Page_02
en HTGD 693 000 V0140 A 1185

2.14.2 HTGD691842V0003B (Page_03)
1186 HTGD 693 000 V0140 A en

2.14.3 HTGD691842V0003B (Page_04)
en HTGD 693 000 V0140 A 1187

2.14.4 HTGD691842V0003B (Page_05)
1188 HTGD 693 000 V0140 A en

2.14.5 HTGD691842V0003B (Page_06)
en HTGD 693 000 V0140 A 1189

2.14.6 HTGD691842V0003B (Page_07)
1190 HTGD 693 000 V0140 A en

2.14.7 HTGD691842V0003B (Page_08)
en HTGD 693 000 V0140 A 1191

2.14.8 HTGD691842V0003B (Page_09)
1192 HTGD 693 000 V0140 A en

2.14.9 HTGD691842V0003B (Page_10)
HTGD691842V0003B - Proximity Sensor0
en HTGD 693 000 V0140 A 1193

2.14.10 HTGD691842V0003B (Page_11)
1194 HTGD 693 000 V0140 A en

2.14.11 HTGD691842V0003B (Page_12)
en HTGD 693 000 V0140 A 1195

2.14.12 HTGD691842V0003B (Page_13)
1196 HTGD 693 000 V0140 A en

2.14.13 HTGD691842V0003B (Page_14)
en HTGD 693 000 V0140 A 1197

2.14.14 HTGD691842V0003B (Page_15)
1198 HTGD 693 000 V0140 A en

2.14.15 HTGD691842V0003B (Page_16)
en HTGD 693 000 V0140 A 1199

2.14.16 HTGD691842V0003B (Page_17)
1200 HTGD 693 000 V0140 A en

2.14.17 HTGD691842V0003B (Page_18)
en HTGD 693 000 V0140 A 1201

2.14.18 HTGD691842V0003B (Page_19)
1202 HTGD 693 000 V0140 A en

2.14.19 HTGD691842V0003B (Page_20)
en HTGD 693 000 V0140 A 1203

2.14.20 HTGD691842V0003B (Page_21)
1204 HTGD 693 000 V0140 A en

2.14.21 HTGD691842V0003B (Page_22)
en HTGD 693 000 V0140 A 1205

2.14.22 HTGD691842V0003B (Page_23)
1206 HTGD 693 000 V0140 A en

2.14.23 HTGD691842V0003B (Page_24)
en HTGD 693 000 V0140 A 1207

2.15 HTGD691842V0005- (Page_01)

HTGD691842V0005- - Proximity Sensor
1208 HTGD 693 000 V0140 A en

2.15.1 HTGD691842V0005- (Page_02)
HTGD691842V0005- - Proximity Sensor_Page_02
en HTGD 693 000 V0140 A 1209

2.15.2 HTGD691842V0005- (Page_03)
1210 HTGD 693 000 V0140 A en

2.15.3 HTGD691842V0005- (Page_04)
en HTGD 693 000 V0140 A 1211

2.15.4 HTGD691842V0005- (Page_05)
1212 HTGD 693 000 V0140 A en

2.15.5 HTGD691842V0005- (Page_06)
en HTGD 693 000 V0140 A 1213

2.15.6 HTGD691842V0005- (Page_07)
1214 HTGD 693 000 V0140 A en

2.15.7 HTGD691842V0005- (Page_08)
en HTGD 693 000 V0140 A 1215

2.15.8 HTGD691842V0005- (Page_09)
1216 HTGD 693 000 V0140 A en

2.15.9 HTGD691842V0005- (Page_10)
HTGD691842V0005- - Proximity Sensor0
en HTGD 693 000 V0140 A 1217

2.15.10 HTGD691842V0005- (Page_11)
1218 HTGD 693 000 V0140 A en

2.15.11 HTGD691842V0005- (Page_12)
en HTGD 693 000 V0140 A 1219

2.15.12 HTGD691842V0005- (Page_13)
1220 HTGD 693 000 V0140 A en

2.15.13 HTGD691842V0005- (Page_14)
en HTGD 693 000 V0140 A 1221

2.16 HTGD691855V0001A (Page_01)

HTGD691855V0001A - Proximity Sensor
1222 HTGD 693 000 V0140 A en

2.16.1 HTGD691855V0001A (Page_02)
HTGD691855V0001A - Proximity Sensor_Page_02
en HTGD 693 000 V0140 A 1223

2.16.2 HTGD691855V0001A (Page_03)
1224 HTGD 693 000 V0140 A en

2.16.3 HTGD691855V0001A (Page_04)
en HTGD 693 000 V0140 A 1225

2.16.4 HTGD691855V0001A (Page_05)
1226 HTGD 693 000 V0140 A en

2.16.5 HTGD691855V0001A (Page_06)
en HTGD 693 000 V0140 A 1227

2.16.6 HTGD691855V0001A (Page_07)
1228 HTGD 693 000 V0140 A en

2.16.7 HTGD691855V0001A (Page_08)
en HTGD 693 000 V0140 A 1229

2.16.8 HTGD691855V0001A (Page_09)
1230 HTGD 693 000 V0140 A en

2.16.9 HTGD691855V0001A (Page_10)
HTGD691855V0001A - Proximity Sensor0
en HTGD 693 000 V0140 A 1231

2.16.10 HTGD691855V0001A (Page_11)
1232 HTGD 693 000 V0140 A en

2.16.11 HTGD691855V0001A (Page_12)
en HTGD 693 000 V0140 A 1233

2.16.12 HTGD691855V0001A (Page_13)
1234 HTGD 693 000 V0140 A en

2.16.13 HTGD691855V0001A (Page_14)
en HTGD 693 000 V0140 A 1235

2.16.14 HTGD691855V0001A (Page_15)
1236 HTGD 693 000 V0140 A en

2.16.15 HTGD691855V0001A (Page_16)
en HTGD 693 000 V0140 A 1237

2.16.16 HTGD691855V0001A (Page_17)
1238 HTGD 693 000 V0140 A en

2.16.17 HTGD691855V0001A (Page_18)
en HTGD 693 000 V0140 A 1239

2.16.18 HTGD691855V0001A (Page_19)
1240 HTGD 693 000 V0140 A en

2.16.19 HTGD691855V0001A (Page_20)
en HTGD 693 000 V0140 A 1241

2.17 HTGD691888V0001B (Page_01)

HTGD691888V0001B - Digital Valve Controller Type DVC2000
1242 HTGD 693 000 V0140 A en

List
2.17.1 HTGD691888V0001B (Page_02)
HTGD691888V0001B - Digital Valve Controller Type DVC2000_Page_02
en HTGD 693 000 V0140 A

1243
2.17.2 HTGD691888V0001B (Page_03)
1244 HTGD 693 000 V0140 A en

List
2.17.3 HTGD691888V0001B (Page_04)
en HTGD 693 000 V0140 A

1245
2.17.4 HTGD691888V0001B (Page_05)
1246 HTGD 693 000 V0140 A en

List
2.17.5 HTGD691888V0001B (Page_06)
en HTGD 693 000 V0140 A

1247
2.17.6 HTGD691888V0001B (Page_07)
1248 HTGD 693 000 V0140 A en

List
2.17.7 HTGD691888V0001B (Page_08)
en HTGD 693 000 V0140 A

1249
2.17.8 HTGD691888V0001B (Page_09)
1250 HTGD 693 000 V0140 A en

List
2.17.9 HTGD691888V0001B (Page_10)
en HTGD 693 000 V0140 A

1251
2.17.10 HTGD691888V0001B (Page_11)
1252 HTGD 693 000 V0140 A en

List
2.17.11 HTGD691888V0001B (Page_12)
en HTGD 693 000 V0140 A

1253
2.17.12 HTGD691888V0001B (Page_13)
1254 HTGD 693 000 V0140 A en

List
2.17.13 HTGD691888V0001B (Page_14)
en HTGD 693 000 V0140 A

1255
2.17.14 HTGD691888V0001B (Page_15)
1256 HTGD 693 000 V0140 A en

List
2.17.15 HTGD691888V0001B (Page_16)
en HTGD 693 000 V0140 A

1257
2.17.16 HTGD691888V0001B (Page_17)
1258 HTGD 693 000 V0140 A en

List
2.17.17 HTGD691888V0001B (Page_18)
en HTGD 693 000 V0140 A

1259
2.17.18 HTGD691888V0001B (Page_19)
1260 HTGD 693 000 V0140 A en

List
2.17.19 HTGD691888V0001B (Page_20)
en HTGD 693 000 V0140 A

1261
2.17.20 HTGD691888V0001B (Page_21)
1262 HTGD 693 000 V0140 A en

List
2.17.21 HTGD691888V0001B (Page_22)
en HTGD 693 000 V0140 A

1263
2.17.22 HTGD691888V0001B (Page_23)
1264 HTGD 693 000 V0140 A en

List
2.17.23 HTGD691888V0001B (Page_24)
en HTGD 693 000 V0140 A

1265
2.17.24 HTGD691888V0001B (Page_25)
1266 HTGD 693 000 V0140 A en

List
2.17.25 HTGD691888V0001B (Page_26)
en HTGD 693 000 V0140 A

1267
2.17.26 HTGD691888V0001B (Page_27)
1268 HTGD 693 000 V0140 A en

List
2.17.27 HTGD691888V0001B (Page_28)
en HTGD 693 000 V0140 A

1269
2.17.28 HTGD691888V0001B (Page_29)
1270 HTGD 693 000 V0140 A en

List
2.17.29 HTGD691888V0001B (Page_30)
en HTGD 693 000 V0140 A

1271
2.17.30 HTGD691888V0001B (Page_31)
1272 HTGD 693 000 V0140 A en

List
2.17.31 HTGD691888V0001B (Page_32)
en HTGD 693 000 V0140 A

1273
2.17.32 HTGD691888V0001B (Page_33)
1274 HTGD 693 000 V0140 A en

List
2.17.33 HTGD691888V0001B (Page_34)
en HTGD 693 000 V0140 A

1275
2.17.34 HTGD691888V0001B (Page_35)
1276 HTGD 693 000 V0140 A en

List
2.17.35 HTGD691888V0001B (Page_36)
en HTGD 693 000 V0140 A

1277
2.17.36 HTGD691888V0001B (Page_37)
1278 HTGD 693 000 V0140 A en

List
2.17.37 HTGD691888V0001B (Page_38)
en HTGD 693 000 V0140 A

1279
2.17.38 HTGD691888V0001B (Page_39)
1280 HTGD 693 000 V0140 A en

List
2.17.39 HTGD691888V0001B (Page_40)
en HTGD 693 000 V0140 A

1281
2.17.40 HTGD691888V0001B (Page_41)
1282 HTGD 693 000 V0140 A en

List
2.17.41 HTGD691888V0001B (Page_42)
en HTGD 693 000 V0140 A

1283
2.17.42 HTGD691888V0001B (Page_43)
1284 HTGD 693 000 V0140 A en

List
2.17.43 HTGD691888V0001B (Page_44)
en HTGD 693 000 V0140 A

1285
2.17.44 HTGD691888V0001B (Page_45)
1286 HTGD 693 000 V0140 A en

List
2.17.45 HTGD691888V0001B (Page_46)
en HTGD 693 000 V0140 A

1287
2.17.46 HTGD691888V0001B (Page_47)
1288 HTGD 693 000 V0140 A en

List
2.17.47 HTGD691888V0001B (Page_48)
en HTGD 693 000 V0140 A

1289
2.18 HTGD691893V0001- (Page_1)

HTGD691893V0001- - Limit Switch
1290 HTGD 693 000 V0140 A en

2.18.1 HTGD691893V0001- (Page_2)
HTGD691893V0001- - Limit Switch_Page_2
en HTGD 693 000 V0140 A 1291

2.18.2 HTGD691893V0001- (Page_3)
1292 HTGD 693 000 V0140 A en

2.18.3 HTGD691893V0001- (Page_4)
en HTGD 693 000 V0140 A 1293

2.18.4 HTGD691893V0001- (Page_5)
1294 HTGD 693 000 V0140 A en

2.18.5 HTGD691893V0001- (Page_6)
en HTGD 693 000 V0140 A 1295

2.19 HTGD691894V0001- (Page_1)

HTGD691894V0001- - Limit switch M22-K10
1296 HTGD 693 000 V0140 A en

2.19.1 HTGD691894V0001- (Page_2)
HTGD691894V0001- - Limit switch M22-K10_Page_2
en HTGD 693 000 V0140 A 1297

2.19.2 HTGD691894V0001- (Page_3)
1298 HTGD 693 000 V0140 A en

2.19.3 HTGD691894V0001- (Page_4)
en HTGD 693 000 V0140 A 1299

2.20 HTGD691895V0001- (Page_1)

HTGD691895V0001- - Switch disconnector P1-32EASVBHI 11
1300 HTGD 693 000 V0140 A en

List
2.20.1 HTGD691895V0001- (Page_2)
HTGD691895V0001- - Switch disconnector P1-32EASVBHI 11_Page_2
en HTGD 693 000 V0140 A 1301

2.20.2 HTGD691895V0001- (Page_3)
1302 HTGD 693 000 V0140 A en

List
2.20.3 HTGD691895V0001- (Page_4)
en HTGD 693 000 V0140 A 1303

2.21 PEPPERL_FUCHS_NCN4_12GM40
PEPPERL_FUCHS_NCN4_12GM40- - Limit Switch Pepperl Fuchs NCN4-12GM40
1304 HTGD 693 000 V0140 A en

List
2.22 ROSEMOUNT_00813_4728- (Page_01)

ROSEMOUNT_00813_4728- - Rosemount 644 Smart Temperature Transmitter
en HTGD 693 000 V0140 A

1305
2.22.1 ROSEMOUNT_00813_4728- (Page_02)
ROSEMOUNT_00813_4728- - Rosemount 644 Smart Temperature Transmit-

ter_Page_02
1306 HTGD 693 000 V0140 A en

List
2.22.2 ROSEMOUNT_00813_4728- (Page_03)

ter_Page_03
en HTGD 693 000 V0140 A 1307

2.22.3 ROSEMOUNT_00813_4728- (Page_04)

ter_Page_04
1308 HTGD 693 000 V0140 A en

List
2.22.4 ROSEMOUNT_00813_4728- (Page_05)

ter_Page_05
en HTGD 693 000 V0140 A 1309

2.22.5 ROSEMOUNT_00813_4728- (Page_06)

ter_Page_06
1310 HTGD 693 000 V0140 A en

List
2.22.6 ROSEMOUNT_00813_4728- (Page_07)

ter_Page_07
en HTGD 693 000 V0140 A 1311

2.22.7 ROSEMOUNT_00813_4728- (Page_08)

ter_Page_08
1312 HTGD 693 000 V0140 A en

List
2.22.8 ROSEMOUNT_00813_4728- (Page_09)

ter_Page_09
en HTGD 693 000 V0140 A 1313

2.22.9 ROSEMOUNT_00813_4728- (Page_10)
ROSEMOUNT_00813_4728- - Rosemount 644 Smart Temperature Transmitter0
1314 HTGD 693 000 V0140 A en

List
2.22.10 ROSEMOUNT_00813_4728- (Page_11)
en HTGD 693 000 V0140 A 1315

2.22.11 ROSEMOUNT_00813_4728- (Page_12)
1316 HTGD 693 000 V0140 A en

List
2.22.12 ROSEMOUNT_00813_4728- (Page_13)
en HTGD 693 000 V0140 A 1317

2.22.13 ROSEMOUNT_00813_4728- (Page_14)
1318 HTGD 693 000 V0140 A en

List
2.22.14 ROSEMOUNT_00813_4728- (Page_15)
en HTGD 693 000 V0140 A 1319

2.22.15 ROSEMOUNT_00813_4728- (Page_16)
1320 HTGD 693 000 V0140 A en

List
2.22.16 ROSEMOUNT_00813_4728- (Page_17)
en HTGD 693 000 V0140 A 1321

2.22.17 ROSEMOUNT_00813_4728- (Page_18)
1322 HTGD 693 000 V0140 A en

List
2.22.18 ROSEMOUNT_00813_4728- (Page_19)
en HTGD 693 000 V0140 A 1323

2.22.19 ROSEMOUNT_00813_4728- (Page_20)

ter_Page_20
1324 HTGD 693 000 V0140 A en

List
2.22.20 ROSEMOUNT_00813_4728- (Page_21)

ter_Page_21
en HTGD 693 000 V0140 A 1325

2.22.21 ROSEMOUNT_00813_4728- (Page_22)

ter_Page_22
1326 HTGD 693 000 V0140 A en

List
2.22.22 ROSEMOUNT_00813_4728- (Page_23)

ter_Page_23
en HTGD 693 000 V0140 A 1327

2.22.23 ROSEMOUNT_00813_4728- (Page_24)

ter_Page_24
1328 HTGD 693 000 V0140 A en

MA -
2.23 WIKA_IN00-05- (Page_1)

WIKA_IN00-05- - Elastic Element Pressure Gauges Selection Installation
Handling and Op-
eration
en HTGD 693 000 V0140 A

1329
2.23.1 WIKA_IN00-05- (Page_2)

Handling
and Operation_Page_2
1330 HTGD 693 000 V0140 A

en
MA -
2.23.2 WIKA_IN00-05- (Page_3)

Handling
en HTGD 693 000 V0140 A

1331
2.23.3 WIKA_IN00-05- (Page_4)

Handling
1332 HTGD 693 000 V0140 A

en
MA -
2.24 WIKA_PM02-06- (Page_1)

WIKA_PM02-06- - Bourdon Tube Pressure Gauge Model 213.40
en HTGD 693 000 V0140 A

1333
2.24.1 WIKA_PM02-06- (Page_2)
WIKA_PM02-06- - Bourdon Tube Pressure Gauge Model 213.40_Page_2
1334 HTGD 693 000 V0140 A en

MA -
2.25 WIKA_PM02-10- (Page_1)

WIKA_PM02-10- - Bourdon Tube Pressure Gauges Model 232.34233.34
en HTGD 693 000 V0140 A

1335
2.25.1 WIKA_PM02-10- (Page_2)
WIKA_PM02-10- - Bourdon Tube Pressure Gauges Model 232.34233.34_Page_2
1336 HTGD 693 000 V0140 A

en
2.26 WIKA_TM53-01- (Page_1)

WIKA_TM53-01- - Bimetal Thermometers Model 53
en HTGD 693 000 V0140 A 1337

2.26.1 WIKA_TM53-01- (Page_2)
WIKA_TM53-01- - Bimetal Thermometers Model 53_Page_2
1338 HTGD 693 000 V0140 A en

List
2.26.2 WIKA_TM53-01- (Page_3)
en HTGD 693 000 V0140 A 1339

2.26.3 WIKA_TM53-01- (Page_4)
1340 HTGD 693 000 V0140 A en

2.27 WIKA_TM55-01- (Page_1)

WIKA_TM55-01- - Bimetal Thermometers Model 55
en HTGD 693 000 V0140 A 1341

2.27.1 WIKA_TM55-01- (Page_2)
1342 HTGD 693 000 V0140 A en

List
2.27.2 WIKA_TM55-01- (Page_3)
en HTGD 693 000 V0140 A 1343

2.27.3 WIKA_TM55-01- (Page_4)
1344 HTGD 693 000 V0140 A en

List
2.27.4 WIKA_TM55-01- (Page_5)
en HTGD 693 000 V0140 A 1345

2.27.5 WIKA_TM55-01- (Page_6)
1346 HTGD 693 000 V0140 A en

en HTGD 693 000 V0140 A 1347

Blank Page
Instrument_List
1348 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
Disassembly and Re-assembly of the HP/LP Turbine Block
MAA10/MAC10 -
HTGD693011V9020 -
the HP/LP Turbine Block
en HTGD 693 000 V0140 A 1349

Revision History
total :
- - (276)
1350 HTGD 693 000 V0140 A en

MAA10/MAC10
- HTGD693011V9020 -
Disassembly and Re-assembly
of the HP/LP Turbine Block
Contents
1 GENERAL
REMARKS ...........................................................................
..........................................1368
1.1 General
information .......................................................................
...................... 1368
1.1.1 Use as
Designed ..........................................................................
........... 1368
1.1.2 Identification of Residual Dangers and Dangerous
Areas....................... 1368
1.1.3
Safety ............................................................................
.......................... 1369
1.1.4 Components and Spare
Parts ................................................................. 1370
1.1.5 Exclusions from
Liability .........................................................................
. 1370
1.2 Information for the operator / owner of the
plant.................................................. 1370
1.2.1 Preparation of
Staff .............................................................................
.... 1371
1.2.2 Safety and Monitoring
Equipment ........................................................... 1371
1.2.3 Safety Rules that
Apply ...........................................................................
1371
1.2.4 Your
Responsibilities...................................................................
............ 1371
1.2.5 Further Duties of the
Operator ................................................................ 1373
1.3 Instructions for the
supervisor.........................................................................
..... 1373
1.3.1 Authorized
Operation .........................................................................
..... 1373
1.3.2 Following Existing Safety
Rules .............................................................. 1373
1.3.3 Responsibilities of the
Supervisors ......................................................... 1373
1.3.4 Manning the Operating
Stand ................................................................. 1374
1.4 Instructions for the operating and maintenance
staff ........................................... 1374
1.4.1 Working with Safety in
Mind .................................................................... 1374
1.4.2 Safe Condition for Maintenance
Work..................................................... 1375
1.4.3 Safety Rules that
Apply ...........................................................................
1375
1.4.4 Questions concerning
Safety .................................................................. 1375
1.4.5 Conduct following
Malfunctions............................................................... 1375
1.4.6 Emergency Shut-
Down ...........................................................................
1375
1.4.7 Denial of Access to Unauthorized
Individuals ......................................... 1376
1.4.8 Reporting Damage and
Defects .............................................................. 1376
1.4.9 Special Tools and Spare
Parts................................................................ 1376
1.4.10 Inspections and
tests..............................................................................
. 1376
1.4.11 Special
Dangers ...........................................................................
........... 1376
2 DISASSEMBLY AND ASSEMBLY
GUIDELINES.........................................................................
...1380
2.1
Introduction ......................................................................
.................................... 1380
2.2
General ...........................................................................
..................................... 1381
2.2.1 Safety
Precautions .......................................................................
........... 1381
2.2.2 Standard Engineering
Practices.............................................................. 1381
2.2.3 Technical Knowledge
Required............................................................... 1382
en HTGD 693 000 V0140 A

1351
& WP4140
2.2.4 Replacement
Parts..............................................................................
.... 1382
2.2.5 Tools and Lifting
Devices ........................................................................
1383
Checks ..........................................................................
1383
2.2.7
Reassembly ........................................................................
.................... 1383
2.2.8
Pipework ..........................................................................
....................... 1384
2.3 Shutting down the
turbine ...........................................................................
......... 1384
2.3.1 Steam Temperature
Distribution ............................................................. 1384
2.3.2 Steam Turbine Shut Down and
Isolation................................................. 1385
2.3.3 Removal of Split-line Insulation
Mats ...................................................... 1385
2.3.4 Removal of the Sound-proof
Structure.................................................... 1385
2.3.5 Pre-dismantling Visual
Checks ............................................................... 1385
2.3.6 Inspections Prior to
Dismantling.............................................................. 1386
2.3.7 Dismantling
Sequence ..........................................................................
.. 1386
2.3.8 Reassembly
Sequence ..........................................................................
. 1386
2.3.9 Inspections After
Reassembly................................................................. 1386
2.4 Lubricating the components and
parts................................................................. 1386
2.4.1 Lubricants for
bladings ..........................................................................
.. 1386
2.4.2 Lubricants for turbine
parts ..................................................................... 1387
2.4.3 Lubricants for
coupling ..........................................................................
.. 1387
2.4.4 Reassembly of Journal and Thrust
Bearings .......................................... 1387
2.4.5 Reassembly of Turbine and Bearing
Housings....................................... 1387
2.4.6 Tightening Torques and Pre-stressing
Forces ........................................ 1387
2.4.7 Special Maintenance
Precautions........................................................... 1388
2.4.8 Test
Certificates ......................................................................
................ 1388
3 DISASSEMBLY
PREPARATIONS ......................................................................
............................ 1390
3.1 Shutting down the

turbine ...........................................................................
......... 1390
3.2 Sound-absorbing
enclosure..........................................................................
....... 1390
3.2.1 Removing the sound-absorbing
enclosure.............................................. 1390
3.2.2 Re-installing the sound-absorbing
enclosure .......................................... 1390
3.3 Turbine
insulation ........................................................................
........................ 1391
3.3.1 Removing the
insulation.........................................................................
. 1391
3.3.2 Re-installing the
insulation ......................................................................
1391
3.4 Isolating the auxiliary
systems ...........................................................................
.. 1391
3.5 Providing the auxiliary
means..............................................................................
1392
3.6 Sequence of
disassembly........................................................................
............ 1392
4 DISASSEMBLY OF THE THRUST BEARING
PEDESTAL ............................................................ 1394
1352 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
4.1
General ...........................................................................
..................................... 1394
4.2
Preparations.......................................................................
.................................. 1394
4.3 Blanking off the lube oil
supply ............................................................................
1394
4.3.1 Removing the plug with
orifice ................................................................ 1395
4.3.2 Re-installing the plug with
orifice............................................................. 1395
4.4 Remove the coupling
cover. ............................................................................
.... 1397
4.5 Removing the
Instruments .......................................................................
............ 1398
4.5.1 Removing the shaft vibration
transmitter................................................. 1398
4.5.2 Removing the Phase-Angle-
Measurement ............................................. 1398
4.5.3 Removing the Shaft Speed
Measurement .............................................. 1399
4.5.4 Blanking off the oil supply to the turning
gear ......................................... 1400
4.6 Lifting off the rotor turning
gear............................................................................
1401
4.6.1
Preparation........................................................................
...................... 1401
4.6.2 Lifting off the rotor turning
gear ............................................................... 1401
4.7 Lifting off the bearing pedestal upper
part ........................................................... 1402
4.7.1 Loosening the flange
joint ....................................................................... 1403
4.7.2 Lifting off the upper
part ..........................................................................
1403
4.8 Check measurements and
tests ..........................................................................
1405
4.8.1 Bearing pedestal upper
part .................................................................... 1405
4.8.2 Bearing pedestal lower
part..................................................................... 1405
4.8.3 Removing the shaft position
monitor ....................................................... 1406
4.8.4 Thermocouples bearing
body.................................................................. 1407
4.8.5 Removing the thermocouples from the bearing
body.............................. 1407
4.9 Removing the thrust bearing, upper
part ............................................................. 1408
4.9.1 Check measurements on the thrust
bearing ........................................... 1408
4.9.2 Removing the thrust bearing, upper
part................................................. 1408
4.9.3 Removing the sets of pads from the thrust
bearing................................. 1410
4.10 Removing the journal bearing, upper
part............................................................ 1410
4.10.1 Check measurements on the journal
bearing.......................................... 1410
4.10.2 Removing the journal bearing, upper
part ............................................... 1411
4.10.3 Installing the rotor raising
device............................................................. 1412
4.11 Removing the thrust / journal bearing lower
parts ............................................... 1413
5 DISMANTLING OF THE
COUPLING ..........................................................................
....................1416
5.1
Preparations.......................................................................
.................................. 1416
5.2 Installing the tensioning
devices ..........................................................................
1417
en HTGD 693 000 V0140 A

1353
& WP4140
5.3 Loosening the coupling

bolts .............................................................................
.. 1417
nuts ............................................................. 1417
sleeves ........................................................... 1418
5.4 Tensioning provisionally the coupling
bolts ......................................................... 1420
5.5
Dismantling .......................................................................
................................... 1420
5.5.1 Installing the tensioning
devices ............................................................. 1420
nuts ............................................................. 1421
sleeves ........................................................... 1421
5.5.4 Loosening the provisionally tensioned coupling
bolts ............................. 1421
5.5.5 Final
work...............................................................................
................. 1421
5.6 Inspecting the
coupling ..........................................................................
.............. 1422
5.6.1 Coupling
components ........................................................................
..... 1422
5.6.2 Coupling
flanges ...........................................................................
.......... 1423
5.6.3 Applying the corrosion
inhibitor ............................................................... 1423
6 DISASSEMBLY OF THE
VALVES ............................................................................
...................... 1426
6.1 Locking the swing arm

support ...........................................................................
. 1427
6.2 Dismantling the stop valve
actuator..................................................................... 1427
6.2.1
Preparations.......................................................................
..................... 1428
6.2.2 Loosening the
coupling ..........................................................................
. 1429
6.2.3 Dismantling the stop valve
actuator ........................................................ 1430
6.3 Dismantling the stop
valve..............................................................................
..... 1431
6.3.1 Check measurements before
dismantling............................................... 1431
6.3.2 Removing the coupling from the valve
spindle........................................ 1432
6.3.3 Dismantling the heat
shield ..................................................................... 1433
6.3.4 Dismantling the intermediate
piece ......................................................... 1433
6.3.5 Dismantling the clamping
ring ................................................................. 1434
6.3.6 Withdrawing the valve
internals .............................................................. 1436
6.3.7 Arranging the disassembly
tools ............................................................. 1436
6.3.8 Removing the valve
internals .................................................................. 1438
diffuser ......................................................................
1439
6.4.1 Loosening the
diffuser...........................................................................
.. 1439
6.4.2 Jacking apart the
diffuser ........................................................................
1440
6.4.3 Mounting the disassembly
tools .............................................................. 1441
6.4.4 Removing the
diffuser ..........................................................................
... 1441
6.5 Disassembling the stop
valve .............................................................................
. 1442
6.6 Dismantling the control valve
actuator................................................................. 1443
6.6.1
Preparations.......................................................................
..................... 1443
1354 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
6.6.2 Loosening the

coupling ..........................................................................
. 1445
6.6.3 Dismantling the control valve
actuator .................................................... 1446
6.7 Dismantling the control
valve .............................................................................
.. 1447
6.7.1 Check measurements before
dismantling ............................................... 1448
6.7.2 Removing the coupling from the valve
spindle........................................ 1448
6.7.3 Dismantling the heat
shield ..................................................................... 1449
6.7.4 Dismantling the intermediate
piece ......................................................... 1449
6.7.5 Dismantling the clamping
ring ................................................................. 1450
6.7.6 Withdrawing the valve
internals............................................................... 1452
6.7.7 Arranging the disassembly
tools ............................................................. 1452
6.7.8 Removing the valve
internals .................................................................. 1454
diffuser .................................................................. 1455
6.8.1 Loosening the
diffuser ..........................................................................
... 1455
6.8.2 Jacking apart the
diffuser ........................................................................
1456
6.8.3 Mounting the disassembly
tools .............................................................. 1456
6.8.4 Removing the
diffuser ..........................................................................
... 1457
6.9 Disassembling the control
valve ..........................................................................
1458
6.10 Disassembling the stop valve
actuator ................................................................ 1459
6.10.1 Putting down the stop valve
actuator ...................................................... 1460
6.10.2 Removing the
cover .............................................................................
... 1462
6.10.3 Relieving and removing the spring
assembly.......................................... 1463
6.11 Disassembling the control valve
actuator ............................................................ 1465
6.11.1 Putting down the control valve
actuator .................................................. 1465
6.11.2 Removing the
cover .............................................................................
... 1467
6.11.3 Relieving and removing the spring
assembly.......................................... 1468
7 DISASSEMBLY OF THE HP/LP
TURBINE ...........................................................................
..........1472
7.1
Preparations.......................................................................
.................................. 1472
7.1.1 Opening the outer
casing ........................................................................
1473
7.1.2 Loosening the bolting of the expansion
joint ........................................... 1474
7.1.3 Loosening the water injection
pipe .......................................................... 1475
7.2 Check measurements before dismantling the outer
casing ................................. 1476
7.2.1 HP
turbine ...........................................................................
.................... 1476
7.2.2 LP
turbine ...........................................................................
..................... 1476
7.3 Dismantling the outer casing upper
half............................................................... 1477
7.3.1 Supporting the HP turbine
casing............................................................ 1477
7.3.2 Loosening the parting flange bolts of the outer
casing............................ 1478
7.3.3 Lifting off the outer casing upper
half ...................................................... 1480
en HTGD 693 000 V0140 A

1355
WP4110 & WP4140
7.4 Check measurements before dismantling the inner

casing ................................. 1482
7.4.1 HP
turbine ...........................................................................
.................... 1482
7.4.2 LP
turbine............................................................................
.................... 1482
7.5 Dismantling the inner casing upper
half............................................................... 1482
7.5.1 Loosening the parting flange bolts of the inner
casing............................ 1482
7.5.2 Lifting off the HP inner casing upper
half ................................................ 1484
7.5.3 Loosening the parting flange bolts of the LP blade
carrier...................... 1485
7.5.4 Lifting off the LP blade carrier upper
part................................................ 1487
7.6 Dismantling the HP shaft
seal..............................................................................
1489
7.7 Dismantling the enclosure and the LP shaft
seal................................................. 1490
7.7.1 Loosening the parting flange bolts of the
enclosure................................ 1490
7.7.2 Dismantling the instruments in the bearing
casing.................................. 1492
7.7.3 Dismantling the LP shaft seal upper
part ................................................ 1494
7.8 Dismantling the journal
bearing ...........................................................................
1495
7.8.1 Dismantling the bearing
bracket.............................................................. 1495
7.8.2 Dismantling the journal bearing upper
part ............................................. 1499
7.8.3 Dismantling the journal bearing lower
part.............................................. 1501
7.9 Check measurements before removing the
rotor ................................................ 1501
7.10 Lifting out the turbine
rotor..............................................................................
..... 1502
8
MAINTENANCE........................................................................
....................................................... 1506
8.1 General
recommendations ...................................................................
............... 1506
8.1.1 Checks and
tests..............................................................................
....... 1506
8.1.2 Cleaning the
components .......................................................................
1506
8.1.3 Marking the dismantled
components ...................................................... 1506
8.1.4 Replacing
components.........................................................................
... 1506
8.1.5
Tools .............................................................................
.......................... 1506
8.1.6 Test
certificates ......................................................................
................. 1506
8.2 Bearing pedestals and turbine
bearings .............................................................. 1507
8.2.1 Foundation
bolts..............................................................................
........ 1507
8.2.2 Bearing
pedestals .........................................................................
.......... 1507
8.2.3 Turbine
bearings ..........................................................................
........... 1507
8.3 Valves and
actuators .........................................................................
.................. 1508
8.3.1
Valves ............................................................................
......................... 1508
8.3.2
Actuators .........................................................................
........................ 1508
8.4
Turbine............................................................................
..................................... 1509
8.4.1 Visual
checks ............................................................................
.............. 1509
1356 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
8.4.2 Cleaning the machine

parts..................................................................... 1509
8.4.3 Turbine
instruments........................................................................
......... 1509
8.4.4 Replacing machine
parts......................................................................... 1510
8.4.5 Re-assembly
recommendations.............................................................. 1510
8.5
Blading ...........................................................................
...................................... 1510
8.5.1 Visual
checks ............................................................................
.............. 1510
8.5.2 Cleaning the
blading............................................................................
.... 1511
8.5.3 Replacing blading
parts...........................................................................
1511
9 RE-ASSEMBLY OF THE HP/LP
TURBINE ...........................................................................
..........1514
9.1 Starting
point..............................................................................
.......................... 1514
9.1.1 Bearing
pedestals..........................................................................
.......... 1514
9.1.2
Turbine ...........................................................................
......................... 1514
9.2 Lifting into place the turbine
rotor......................................................................... 1514
9.2.1 Installing the lifting
device ....................................................................... 1514
9.2.2 Lifting into place the
rotor ........................................................................ 1515
9.2.3 Check measurements after lifting into place the
rotor ............................. 1517
9.3 Re-installing the journal
bearing ..........................................................................
1518
9.3.1 Installing the journal bearing upper
part .................................................. 1519
9.3.2 Check measurements after installing the
bearing ................................... 1520
9.3.3 Installing the bearing
bracket .................................................................. 1521
9.4 Re-installing the LP shaft seal and
enclosure...................................................... 1523
9.4.1 Installing the LP shaft
seal ...................................................................... 1523
9.4.2 Installing the
instruments........................................................................
. 1526
enclosure..........................................................................
.. 1527
9.5 Re-installing the HP shaft
seal.............................................................................
1529
9.6 Re-mounting the inner casing upper
parts........................................................... 1531
9.6.1 Lifting into place the LP blade carrier upper
part..................................... 1531
9.6.2 Tightening the parting flange bolts of the LP blade
carrier...................... 1533
9.6.3 Lifting into place the HP inner casing upper
half ..................................... 1535
9.6.4 Tightening the parting flange bolts of the HP inner
casing...................... 1537
9.7 Check measurements before re-mounting the outer
casing ................................ 1538
9.7.1 HP
turbine ...........................................................................
.................... 1538
9.7.2 LP
turbine ...........................................................................
..................... 1538
9.8 Re-mounting the outer casing upper
half............................................................. 1538
9.8.1 Lifting into place the outer casing upper
half........................................... 1538
9.8.2 Tightening the parting flange bolts of the outer
casing............................ 1540
9.8.3 Securing the HP shaft
seal...................................................................... 1543
en HTGD 693 000 V0140 A

1357
WP4110 & WP4140
9.8.4 Loosening the HP casing

support ........................................................... 1543
9.9 Check measurements after re-mounting the outer
casing................................... 1545
9.9.1 HP
turbine ...........................................................................
.................... 1545
9.9.2 LP
turbine............................................................................
.................... 1545
9.10 Additional
work ..............................................................................
...................... 1546
9.10.1 Installing the water injection
pipe ............................................................ 1546
9.10.2 Installing the expansion joint
bolting ....................................................... 1547
9.10.3 Installing the rupture diaphragm and refitting the manhole
covers ......... 1549
9.11 Final
remarks ...........................................................................
............................ 1550
VALVES.............................................................................
..................... 1552
10.1 Re-installing the control valve

diffuser ................................................................. 1552
diffuser ..........................................................................
..... 1553
10.1.2 Screwing together the
diffuser ................................................................ 1554
10.2 Re-installing the control
valve..............................................................................
1555
10.2.1 Arranging the assembly
tools.................................................................. 1555
10.2.2 Inserting and moving into place the valve
internals ................................ 1556
10.2.3 Installing the segment
ring ...................................................................... 1558
10.2.4 Installing the intermediate
piece.............................................................. 1559
10.2.5 Mounting the coupling parts and heat
shield........................................... 1560
actuator................................................................ 1561
10.3.1 Attaching the control valve actuator to the
valve..................................... 1562
10.3.2 Connecting the actuator and the
valve.................................................... 1563
10.4 Re-installing the stop valve
diffuser ..................................................................... 1565
diffuser ..........................................................................
..... 1565
10.4.2 Screwing together the
diffuser ................................................................ 1567
10.5 Re-installing the stop
valve..............................................................................
.... 1567
10.5.1 Arranging the assembly
tools.................................................................. 1568
10.5.2 Inserting and moving into place the valve
internals ................................ 1569
10.5.3 Installing the segment
ring ...................................................................... 1571
10.5.4 Installing the intermediate
piece.............................................................. 1572
10.5.5 Mounting the coupling parts and heat
shield........................................... 1573
actuator.................................................................... 1575
10.6.1 Attaching the stop valve actuator to the
valve......................................... 1575
10.6.2 Connecting the actuator and the
valve.................................................... 1576
10.7 Moving the swing arm support into the operating
position................................... 1578
10.8 Final
work ..............................................................................
.............................. 1578
1358 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
10.8.1 Electrical
connections........................................................................
...... 1579
10.8.2 Hydraulic pressure
supply ....................................................................... 1579
10.9 Stroke test of the
valves.............................................................................
.......... 1579
10.9.1 Stop valve with
actuator ..........................................................................
1579
10.9.2 Control valve with
actuator ......................................................................
1579
COUPLING ..........................................................................
...................1582
11.1
Preparations.......................................................................
.................................. 1582
11.2 Pulling together the coupling
flanges ................................................................... 1583
11.3 Aligning the
coupling...........................................................................
................. 1584
11.3.1 Checking the
parallelism .......................................................................
.. 1584
11.3.2 Measuring the angular
misalignment ...................................................... 1585
11.3.3 Correcting the angular
misalignment....................................................... 1585
11.4 Centring the
coupling ..........................................................................
................. 1586
11.4.1
Preparations ......................................................................
...................... 1586
11.4.2 Centring the coupling
bores .................................................................... 1586
11.4.3 Pulling together the
coupling ................................................................... 1587
11.4.4 Tensioning radially the centring
sleeves ................................................. 1588
11.4.5 Tensioning provisionally the coupling
bolts ............................................. 1589
11.5 Tensioning definitely the coupling
bolts ............................................................... 1589
11.5.1 Inserting the coupling
bolts...................................................................... 1590
11.5.2 Mounting the tensioning
device............................................................... 1590
11.5.3 Pre-tensioning the coupling
bolts ............................................................ 1591
11.5.4 Measuring the fitting
clearance ............................................................... 1592
11.5.5 Screwing on and marking the countersunk
nuts ..................................... 1592
11.5.6 Tensioning the coupling
bolts.................................................................. 1592
11.5.7 Removing the provisionally inserted coupling
bolts................................. 1593
11.5.8 Removing the centring
sleeves ............................................................... 1594
11.5.9 Pre-tensioning the remaining coupling
bolts ........................................... 1594
11.5.10 Tensioning definitely the coupling
bolts................................................... 1595
11.5.11 Checking the coupling
assembly............................................................. 1595
11.5.12 Securing the countersunk
nuts................................................................ 1595
11.6 Checking the concentric
run ...............................................................................
. 1596
11.7 Final
work...............................................................................
.............................. 1597
12 RE-ASSEMBLY OF THE THRUST BEARING
PEDESTAL ............................................................1600
12.1 Starting
point..............................................................................
.......................... 1600
12.2 Installing the
bearings ..........................................................................
................ 1600
en HTGD 693 000 V0140 A

1359
WP4110 & WP4140
12.2.1 Installing the combined thrust and journal bearing lower

part................. 1600
12.2.2 Removing the shaft raising
device .......................................................... 1601
12.2.3 Lifting in the journal bearing, upper
part.................................................. 1602
12.3 Mounting the thrust bearing, upper
part............................................................... 1604
12.3.1 Installing the sets of
pads........................................................................ 1604
12.3.2 Installing the thrust bearing, upper
part................................................... 1604
12.4 Check measurements after installing the
bearing................................................ 1607
12.4.1 Bearing
clearances ........................................................................
......... 1607
12.4.2 Rotor
position ..........................................................................
................ 1608
12.5 Inserting the
thermocouples .....................................................................
........... 1608
12.6 Installing the oil shield lower
parts ....................................................................... 1608
12.7 Installing the shaft position
monitor ..................................................................... 1609
12.8 Re-installing the bearing pedestal upper
part ...................................................... 1610
12.8.1
Preparations.......................................................................
..................... 1610
12.8.2 Lifting into place the upper
part............................................................... 1610
12.9 Lifting the rotor turning gear into
place ................................................................ 1612
12.10 Adjusting the oil
shields ...........................................................................
............ 1613
12.11 Connecting the oil supply of the turning
gear ...................................................... 1614
12.12 Installing the
instruments .......................................................................
.............. 1615
12.12.1 Measured value
transmitter.....................................................................
1615
12.12.2 Electrical
connections .......................................................................
...... 1615
12.12.3 Checking the
adjustments.......................................................................
1616
12.13 Refit the coupling
cover. ............................................................................
.......... 1617
12.14 Connecting the oil supply to the bearing
pedestal ............................................... 1617
12.14.1 Removing the
plug ..............................................................................
.... 1617
12.14.2 Re-installing the plug with
orifice............................................................. 1618
12.15 Final work and final
checks.............................................................................
..... 1619
12.15.1 Check
measurements ......................................................................
....... 1619
12.15.2 Final
remarks ...........................................................................
............... 1619
13 FINAL
WORK ..............................................................................
.................................................... 1622
13.1 Adjusting the operating

positions.........................................................................
1622
13.2 Pipelines and pipe
unions.............................................................................
....... 1622
13.3 Expansion
joint .............................................................................
....................... 1622
1360 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
HP/LP Turbine Block
13.4 Power
supply ............................................................................
........................... 1622
13.4.1 Connecting the auxiliary
systems............................................................ 1622
13.4.2 Bearing
pedestals..........................................................................
.......... 1623
13.4.3 Valve
actuators..........................................................................
.............. 1623
13.4.4
Turbine ...........................................................................
......................... 1623
13.5 Lube oil supply to the bearing
pedestals.............................................................. 1623
13.6 Functioning of the valve
actuators .......................................................................
1624
13.6.1 Stop valve
actuators..........................................................................
...... 1624
13.6.2 Control valve
actuators..........................................................................
.. 1624
13.7 Auxiliary
systems ...........................................................................
...................... 1624
13.8 Insulation and
enclosure .........................................................................
............. 1624
13.8.1
Insulation ........................................................................
......................... 1624
13.8.2 Sound-absorbing
enclosure .................................................................... 1624
13.9 Checks and final
work...............................................................................
........... 1624
en HTGD 693 000 V0140 A

1361
WP4110 & WP4140
Figures
Fig. 4-1 Removing the plug with

orifice ...........................................................................
........ 1396
Fig. 4-2 Removing the coupling
cover .............................................................................
........ 1398
Fig. 4-3 Arrangement of the
instruments .......................................................................
.......... 1399
Fig. 4-4 Blanking off the oil supply to the turning
gear ............................................................ 1400
Fig. 4-5 Lifting off the rotor turning
gear ..............................................................................
.... 1402
Fig. 4-6 Lifting off the upper
part ..............................................................................
............... 1404
Fig. 4-7 Removing the oil shield lower
parts............................................................................
1406
thermocouples .....................................................................
....... 1407
Fig. 4-9 Removing the thrust bearing upper
part..................................................................... 1409
Fig. 4-10 Removing the journal bearing upper
part ................................................................. 1411
Fig. 4-11 Installing the rotor raising
device.............................................................................
. 1413
Fig. 5-1 Bending back the locking
rings..............................................................................
..... 1416
Fig. 5-2 Installing the tensioning
devices............................................................................
..... 1417
Fig. 5-3 Installing the extension
tube...............................................................................
........ 1418
Fig. 5-4 Loosening the expansion
sleeves ...........................................................................
... 1419
bolts ................................................................ 1420
Fig. 5-6 Loosening the provisionally tensioned coupling
bolts ................................................ 1421
Fig. 5-7 Forcing the coupling flanges out of the
recess........................................................... 1422
assembly ..........................................................................
.............. 1426
Fig. 6-2 Locking the swing arm
support............................................................................
....... 1427
coupling ..........................................................................
.................... 1429
Fig. 6-4 Dismantling the stop valve
actuator ..........................................................................
. 1430
Fig. 6-5 Dismantling the coupling and heat
shield................................................................... 1432
Fig. 6-6 Dismantling the intermediate
piece ............................................................................
1434
Fig. 6-7 Dismantling the clamping
ring ..............................................................................
...... 1435
Fig. 6-8 Withdrawing the valve
internals..........................................................................
........ 1436
tools .............................................................................
............... 1437
1362 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
Fig. 6-10 Removing the valve

internals .........................................................................
.......... 1438
diffuser ..........................................................................
.................... 1439
Fig. 6-12 Jacking apart the
diffuser ..........................................................................
............... 1440
Fig. 6-13 Mounting the
tools .............................................................................
....................... 1441
Fig. 6-14 Removing the valve spindle and
bushings ............................................................... 1443
coupling...........................................................................
.................. 1445
Fig. 6-16 Dismantling the control valve
actuator...................................................................... 1446
Fig. 6-17 Dismantling the coupling and heat
shield ................................................................. 1448
Fig. 6-18 Dismantling the intermediate
piece ..........................................................................
1450
Fig. 6-19 Dismantling the clamping
ring ..............................................................................
.... 1451
Fig. 6-20 Withdrawing the valve
internals..........................................................................
...... 1452
Fig. 6-21 Dismantling the valve
internals..........................................................................
....... 1453
Fig. 6-22 Removing the valve
internals .........................................................................
.......... 1454
diffuser ..........................................................................
.................... 1455
Fig. 6-24 Jacking apart the
diffuser ..........................................................................
............... 1456
tools .............................................................................
............. 1457
Fig. 6-26 Dismantling the valve spindle and
bushings............................................................. 1459
Fig. 6-27 Putting down the stop valve
actuator........................................................................
1461
Fig. 6-28 Dismantling the
cover .............................................................................
.................. 1462
Fig. 6-29 Relieving the spring
assembly...........................................................................
....... 1464
Fig. 6-30 Putting down the control valve
actuator.................................................................... 1466
cover .............................................................................
.................. 1467
Fig. 6-32 Relieving the spring
assembly...........................................................................
....... 1469
Fig. 7-1 Opening the outer
casing ............................................................................
............... 1473
Fig. 7-2 Loosening the bolting of the expansion
joint .............................................................. 1474
Fig. 7-3 Separating the
pipes..............................................................................
..................... 1475
Fig. 7-4 Preparing the measurement
plane .............................................................................
1476
Fig. 7-5 Supporting the turbine
casing.............................................................................
........ 1477
Fig. 7-6 Loosening the parting flange
bolts..............................................................................
1479
en HTGD 693 000 V0140 A

1363
WP4110 & WP4140
Fig. 7-7 Lifting off the outer casing upper

half ......................................................................... 1481
Fig. 7-8 Loosening the parting flange bolts of the inner
casing ............................................... 1484
Fig. 7-9 Loosening the parting flange bolts of the LP blade
carrier ......................................... 1487
Fig. 7-10 Dismantling the shaft seal upper
part....................................................................... 1489
Fig. 7-11 Loosening the parting flange bolts of the
enclosure................................................. 1491
instruments .......................................................................
.............. 1493
Fig. 7-13 Dismantling the shaft seal upper
part....................................................................... 1494
Fig. 7-14 Dismantling the bearing
bracket............................................................................
... 1497
Fig. 7-15 Dismantling the journal bearing upper
part .............................................................. 1499
device.............................................................................
. 1501
Fig. 7-17 Lifting out the
rotor .............................................................................
...................... 1503
Fig. 9-1 Lifting into place the turbine
rotor .............................................................................
.. 1516
Fig. 9-2 Installing the journal bearing upper
part ..................................................................... 1519
Fig. 9-3 Installing the bearing
bracket ...........................................................................
.......... 1522
Fig. 9-4 Installing the shaft seal upper
part .............................................................................
1524
Fig. 9-5 Installing the
instruments........................................................................
.................... 1526
enclosure..........................................................................
..................... 1528
Fig. 9-7 Re-installing the shaft seal upper
part........................................................................ 1530
Fig. 9-8 Re-installing the LP blade carrier upper
part.............................................................. 1533
Fig. 9-9 Re-mounting the HP inner casing upper
part ............................................................. 1536
Fig. 9-10 Lifting on the outer casing upper
half ....................................................................... 1539
Fig. 9-11 Tightening the parting flange
bolts ...........................................................................
1542
Fig. 9-12 Loosening the casing
support ...........................................................................
....... 1544
Fig. 9-13 Closing off the measurement
plane..........................................................................
1545
pipe ..............................................................................
....................... 1546
Fig. 9-15 Installing the expansion joint
bolting.........................................................................
1548
Fig. 9-16 Mounting the rupture
diaphragm .........................................................................
..... 1549
assembly ..........................................................................
............ 1552
diffuser ..........................................................................
...................... 1553
1364 HTGD 693 000 V0140 A

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HTGD693011V9020 -
Fig. 10-3 Screwing together the

diffuser...........................................................................
....... 1554
Fig. 10-4 Arranging the
tools .............................................................................
...................... 1556
Fig. 10-5 Moving into place the control valve
internals............................................................ 1557
Fig. 10-6 Installing the segment
ring...............................................................................
......... 1558
Fig. 10-7 Installing the intermediate
piece .............................................................................
.. 1559
Fig. 10-8 Mounting the coupling and heat
shield ..................................................................... 1561
Fig. 10-9 Mounting the control valve
actuator..........................................................................
1563
Fig. 10-10 Connecting the control valve actuator and the
valve.............................................. 1564
diffuser...........................................................................
.................... 1565
Fig. 10-12 Screwing together the
diffuser...........................................................................
..... 1567
Fig. 10-13 Arranging the
tools .............................................................................
.................... 1568
Fig. 10-14 Moving into place the stop valve
internals.............................................................. 1570
Fig. 10-15 Installing the segment
ring...............................................................................
....... 1571
Fig. 10-16 Installing the intermediate
piece .............................................................................
1572
Fig. 10-17 Mounting the coupling and the heat
shield ............................................................. 1574
Fig. 10-18 Mounting the stop valve
actuator...........................................................................
. 1576
Fig. 10-19 Connecting the stop valve actuator and the
valve.................................................. 1577
Fig. 10-20 Operating position of the swing arm
support .......................................................... 1578
flanges........................................................................
1583
Fig. 11-2 Inserting the jack
screws ............................................................................
.............. 1584
Fig. 11-3 Centring the coupling
bores..............................................................................
........ 1586
Fig. 11-4 Pulling together the
coupling ..........................................................................
.......... 1587
Fig. 11-5 Tensioning radially the centring
sleeves................................................................... 1588
bolts .............................................................. 1589
Fig. 11-7 Inserting the coupling
bolts..............................................................................
......... 1590
Fig. 11-8 Mounting the tensioning
device ............................................................................
.... 1591
Fig. 11-9 Pre-tensioning the coupling
bolts .............................................................................
1592
Fig. 11-10 Removing the provisionally inserted coupling
bolts................................................ 1593
Fig. 11-11 Removing the centring
sleeves ...........................................................................
... 1594
en HTGD 693 000 V0140 A

1365
& WP4140
Fig. 11-12 Tensioning definitely the coupling

bolts.................................................................. 1595
Fig. 11-13 Bending the locking
rings .............................................................................
.......... 1596
Fig. 12-1 Removing the shaft raising
devices..........................................................................
1601
Fig. 12-2 Lifting in the journal bearing upper
part.................................................................... 1603
Fig. 12-3 Installing the thrust bearing, upper
part.................................................................... 1606
thermocouples .....................................................................
..... 1608
Fig. 12-5 Installing the oil shield lower
parts............................................................................
1609
Fig. 12-6 Lifting into place the bearing pedestal upper
part .................................................... 1611
Fig. 12-7 Lifting the rotor turning gear into
place..................................................................... 1613
Fig. 12-8 Connecting the oil
supply ............................................................................
............. 1614
instruments........................................................................
.................. 1616
Fig. 12-10 Refiting the coupling
cover .............................................................................
........ 1617
Fig. 12-11 Refiting the plug with
orifice ...........................................................................
........ 1618
Component description of the thrust/journal bearing
Synopsis of test certificates
Bolt tensioning device, torque screw driver
Bolt tensioning devices, stretching method
Hydraulic stretching of elongation bolts
Inspection plans for turbines
Hydraulically pre-tensioned foundation bolts
Removal of salt and silica from steam turbines
Turbine insulation
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CHAPTER 1
GENERAL REMARKS
en HTGD 693 000 V0140 A 1367

1 GENERAL REMARKS
Introduction
This chapter comprises four sections:
1.1 General Information
1.2 Information for the operator / owner of the installation;
1.3 Information for the plant supervisor;
1.4 Information for the operating and maintenance staff
Note
The operating and maintenance staff must read Sections 1.1, "General
Informa-
tion," and 1.4, "Information for the Operating and Maintenance Staff."
The owner/operator and the supervisor must be familiar with the entire
document.
1.1 General information

1.1.1 Use as Designed
The following points must be noted to ensure that the machine (gas turbine,
steam
turbine, or generator) will be used as intended:
a) The operating instructions for the individual systems, blocks, and
components de-
fine their respective use as designed.
b) The machine may only be used within the permissible operating ranges.
1.1.2 Identification of Residual Dangers and Dangerous Areas

Symbols in the operating instructions highlight special safety rules.
DANGER
Indicates an imminently hazardous situation which, if not avoided, will
result
in death or serious injury. This signal word is to be limited to the most
ex-
treme situation.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could
result
in death or serious injury.
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Disassembly and Re-assembly of the HP/LP
Turbine Block
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may
result
in minor or moderate injury. It may also be used to alert against unsafe
prac-
tices.
Caution
Note
12
Informs the user of the relevant Parts List where further details of each
com-
1.1.3 Safety
The plant has been designed according to state-of-the-art technology (at
the time of
its production) and complies with the generally recognized safety
regulations. All the
same, dangers may arise when operating the plant. To limit these dangers,
always
pay attention to all of the instructions in the operating instructions
and to all safety
rules.
WARNING
Hazardous operation
Operate the plant only when it is in a proper condition and always
follow the op-
erating instructions.
Operating safety is no longer guaranteed if the plant is used

inappropriately. Here
some examples of inappropriate use:
a) Faulty maintenance work
b) Omission of tests and measurements that also serve to detect defects
at an early
stage
c) Non-compliance with maintenance intervals
d) Operation without the prescribed safety devices
e) Operation of the plant, blocks, or components in a manner other than
as designed
en HTGD 693 000 V0140 A
1369
Note
Inappropriate use renders any and all liability on the part of the
manufacturer null
and void.
1.1.4 Components and Spare Parts

All plant components and accessories have been designed, selected, and
approved
by Alstom especially for this plant. This applies only if Alstom has made
the delivery
and bears overall responsibility for it.
The installation or use of spare parts other than those approved by ALSTOM
can
change the characteristics of the plant and impair safety of operation.
1.1.5 Exclusions from Liability

Alstom excludes liability for any damage resulting from:
a) the use of parts not expressly approved and supplied by ALSTOM (This may
also
apply to parts included in the original delivery)
b) inappropriate handling of the plant or parts thereof during transport,
storage, as-
sembly, operation, maintenance, etc.
c) force majeure (Acts of God) and normal wear
d) the intrusion of third parties
e) overstressing
f) inappropriate tools or operating materials
g) Extreme ambient temperatures
h) air pollution, relative humidity, radioactivity, fluctuations in voltage
and/or tem-
peratures
i) failure to comply with safety regulations
j) any change or modification to the safety equipment that has not
expressly been
approved beforehand in writing by ALSTOM
k) any other cause that does not fall within the responsibilities of ALSTOM
1.2 Information for the operator / owner of the plant

Inappropriate operation of the plant causes danger to man and machine, For
this
reason, the operating personnel must be trained in plant assembly,
operation, and
maintenance.
The dangers involved include, among others:
a) danger to life and limb of operating staff and other individuals
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Disassembly and Re-assembly of the HP/LP Turbine
Block
b) damage to the plant

c) environmental pollution
d) impairment of plant performance and function
1.2.1 Preparation of Staff

Every individual whose assignments include assembly, operation, or
maintenance of
the machine must read, understand, and follow the relevant sections of
these in-
structions, "General Safety Rules." You must provide appropriate training
for this !
1.2.2 Safety and Monitoring Equipment
WARNING
Safety / Monitoring
Do not alter the installed safety and monitoring equipment!
1.2.3 Safety Rules that Apply

Make certain that your employees have access to local safety and accident
regula-
tions that apply at their workstation.
Here, for reference, a few regulations that apply in Germany and in
Switzerland:
a) General Accident Prevention Regulations, VGB1
b) Noise Protection Regulations, VGB121
c) Regulations for Safety Marking at the Workplace, VGB125
d) Regulations for Electrical Plant and Equipment
e) Safety Rules for Generators per DIN 57105 Sheet 1, VDE0150 Part 1
f) Firefighting in the Area of Electrical Installations, VDE 0132
g) Further pertinent guidelines, e.g.,: VDE0100 / 0101 / 0107
h) Regulations covering Power Tools, VGB5 �2 Para. 1
1.2.4 Your Responsibilities

As the plant operator, you are responsible for operating it as designed and
according
to safety regulations.
Note
Do not make any compromise at the cost of safety !
Your employees must be able to act with safety in mind. To ensure this:
en HTGD 693 000 V0140 A

1371
a) If there are not already alarm plans and rules of conduct existing for
cases of
emergency, prepare such plans and rules.
b) Instruct your employees to maintain the plant in a clean and manageable
condi-
tion and make certain that such instructions are followed.
c) Prepare company-internal safety and work procedures.
d) Appoint a safety director and make certain that he either has the
necessary know-
how or obtains it promptly.
e) Define responsibilities and authority. Unclear authority can detract from
safety.
f) Define which personnel must be at which workstation while the plant is in
opera-
tion.
g) Train your employees for their assignments.
h) Have your employees confirm in writing their receipt of the procedures
and their
participation in the training courses and drills.
i) Carefully drill your employees.
j) Your employees must have available to them personal safety gear (eye,
ear, feet,
body protectors, helmets, etc.).
k) Every employee must have read and understood the section that applies to
him
before starting to carry out any activities in the plant.
l) Only individuals who understand the language and content of the relevant
sec-
tions of the operating instructions may carry out work in the plant.
m) Every employee must have access to the operating instructions and, in
particular,
the safety rules.The operating staff is to be given access to the
following instruc-
tions:
1) For generators and all other electrical facilities:
� first aid following accidents involving electricity
� information sheet on fighting fires in electrical plants and their
vicinity
2) For turbines:
� Instructions for First Aid in Case of Accidents, for reference
VDE0134 or
ZH/403
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1.2.5 Further Duties of the Operator
Note
You alone, the operator, are responsible for fulfilling the inspection
duties (the ac-
ceptance report for safety).
Make sure that dangers in the workplace are identified with clear safety
markings in-
telligible at the plant location. Also make sure that zones to which no
access is per-
missible (e.g., during operation) are clearly identified. This also
includes identification
of noisy areas.
Note
The identification of danger zones frees you neither from observing the
applicable
safety rules and regulations, nor from checking to see that such rules are
being fol-
lowed by others.
Implement the safety measures described in the general rules and

regulations and in
the operating instructions.
1.3 Instructions for the supervisor

1.3.1 Authorized Operation
The machine may be operated and maintained only by trained and authorized
oper-
ating staff.
The responsibilities of the staff for the various activities at the plant
must be defined
clearly.
Note
From the point of view of safety, no unclearly defined authority is
permissible. This
is particularly the case when working on electrical, control, hydraulic,
and pneu-
matic equipment. Such work must only be carried out by technical staff
trained
specifically for these activities and familiar as well with special local
governmental
provisions and requirements.
1.3.2 Following Existing Safety Rules

Always follow the applicable accident prevention and safety rules of the
country in-
volved when erecting, working on, and operating the plant.
1.3.3 Responsibilities of the Supervisors

a) Make sure that your fellow employees read and understand the pertinent
instruc-
tions in the operating instructions, particularly the information
therein that is rele-
vant to safety.
en HTGD 693 000 V0140 A

1373
b) Familiarize yourself with the operating instructions and the activities

relevant to
safety.
c) As supervisor, you are also responsible for removing any deficiencies
relevant to
safety. Instruct your employees to inform you immediately of any safety
deficien-
cies.
d) Explain to your employees the dangers involved with noise, fatigue, and
psycho-
logical stress.
e) Make sure that the intervals for maintenance and inspections are
maintained.
f) Check regularly the condition of your special tools and spare parts
yourself, or
make sure that your employees take over and perform this inspection
work.
1.3.4 Manning the Operating Stand

Do not start the plant into operation until the prescribed staff trained to
operate the
plant is ready for work.
Prior to starting into operation, make sure that the alarm plans and other
documents
pertaining to safety are readily available.
1.4 Instructions for the operating and maintenance staff

1.4.1 Working with Safety in Mind
Pay particular attention to the following safety rules:
a) Help make your workplace safe ! Only carry out tasks that you are
authorized to
handle and for which you have read the operating instructions and
understood
them completely.
b) Follow the instructions of the safety director and his technical staff.
c) Use the safety equipment and wear the prescribed protective gear in the
danger-
ous working areas.
Note particularly:
a) Applicable safety and accident prevention procedures
b) Do not remove or disable safety devices (protective caps, etc.)
c) Follow "No smoking" rules
d) Do not carry out any work that may impair safety. For example:
� No work on or in systems that have not been disconnected (blocked)
� No work on systems under pressure or with high temperature
� No work on systems that are electrically live
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e) Use the safety equipment

f) Wear protective clothing where necessary or prescribed
g) Wear the prescribed ear protection where necessary
h) Remain at the workplace prescribed in the operating instructions while
the plant is
in operation.
1.4.2 Safe Condition for Maintenance Work

Only carry out work on the plant or on a system when it is in a non-
operating state
permissible for doing such work. Refer to the operating instructions for
the necessary
switch and equipment settings.
Secure sections of the plant that have been disconnected to prevent them
from start-
ing up accidentally. Remove the key from the key-operated switch, remove
the
fuses, and post notices to warn against restarting the plant or section of
the plant.
Make sure before starting the maintenance work that the turbine and all
interface
systems are shut down, drained, pressure-free, temperature-less and secured
against switching on
1.4.3 Safety Rules that Apply

Pay attention to the applicable safety and accident prevention procedures
when
erecting, commissioning, operating, doing maintenance, and repairing the
machine.
1.4.4 Questions concerning Safety

Contact your safety director or supervisor immediately whenever you have
any ques-
tions concerning safety or detect dangers.
Your safety director or your superior will provide you with the safety
regulations that
apply for you.
1.4.5 Conduct following Malfunctions

Note the operating parameters and warning and malfunction reports and carry
out
the checking prescribed.
Note
React immediately to warning and malfunction reports and conduct yourself
ac-
cording to the regulations, operating instructions, and alarm plans.
1.4.6 Emergency Shut-Down

In case of obvious dangers (fire, unusual noise, escaping steam, oil, or
gas, glowing,
etc.) use the manual emergency shut-off.
en HTGD 693 000 V0140 A
1375
1.4.7 Denial of Access to Unauthorized Individuals

Only authorized individuals who are familiar with at least the minimum
safety rules
are granted access to the plant and the individual components thereof.
Even em-
ployees of the operator have no access unless explicitly authorized.
1.4.8 Reporting Damage and Defects

Inspect the plant once per shift for damage visible externally.
Report immediately any changes that impair the safety or reliability of
the plant.
These also include unusual vibrations and sound.
1.4.9 Special Tools and Spare Parts

Keep the special tools and spare parts supplied by the manufacturer ready
for use.
Keep them clean and store them in a dry place. In addition, follow the
operating in-
structions for them.
1.4.10 Inspections and tests

Carry out all inspections and tests on machines and equipment in
accordance with
the Alstom guidelines and recommendations.
Use copies of the test certificates and data sheets for recording the
results of inspec-
tions and tests.
Send the completed forms to the Alstom Service Department.
1.4.11 Special Dangers

1. Shipment, Machine Assembly
Use only the fastening points, suspensions, and support and transport
equipment
detailed in the operating instructions.
This also applies for the disassembly and assembly done during maintenance
and
repair work.
2. Initial Start-Up after a Standstill for Maintenance Work
Special rules apply here. It is not permissible to enter potentially
dangerous zones.
Note
These may also include zones which may be entered during normal operation.
Such initial start-ups may only be carried out by qualified staff. This
staff must under-
stand the construction and operation of the plant and follow the operating
instruc-
tions.
3. Standstill
Take the precautions customary locally with regard to preventing the
escape of com-
bustible or poisonous liquid, gas or steam.
1376 HTGD 693 000 V0140 A
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Escaping gas or liquid presents the risk of an explosion when doing welding
(gas or
fuel leakage).
WARNING
Risk of poisoning / Risk of explosion
It is not permissible to enter the machine if gas or steam is escaping.
4. Protective Covers
Regularly check the protective covers on rotating machine parts to make sure
they fit
correctly and are secure.
If you have removed the protective covers for maintenance or repair work,
secure
them in place again with the locking elements provided for this purpose before
you
recommmission the machine. Only then has the work been completed.
5. Danger of Fire
Keep inflammable materials away from the turbine. It is not permissible to
store in-
flammable materials near the turbine. Be particularly careful to keep liquid
media of
any kind away from the insulation on the generators and the turbines.
6. Noise
Wear ear protectors in the designated noise zones.
7. Danger of Explosions
Note the explosion danger zones. In these zones, in accordance with the
explosion
protection documents, safety procedures (conduct, access, marking) and
restrictions
(tools, clothing, structural modifications) must be observed.
8. Power Supply System
No work is permitted on the DC power supply and the uninterruptible power
supply
(UPS) while the machine is running.
9. Lifting Equipment Loads
When using lifting gear, cranes, etc., make sure that such equipment is not
over-
loaded. Refer to the operating instructions for the weights of the individual
machine
parts.
10.Cleaning Agents and Lubricants
Use only the cleaning agents or lubricants specified or recommended by Alstom.
Alstom has tested the characteristics of these materials.
11.Aggressive and Environmentally Harmful Media
Follow all safety regulations when handling these media and observe the
regulations
covering their disposal.
en HTGD 693 000 V0140 A
1377
Blank Page
1378 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 2
DISASSEMBLY AND ASSEMBLY GUIDELINES
en HTGD 693 000 V0140 A 1379

2 DISASSEMBLY AND ASSEMBLY GUIDELINES
2.1 Introduction
This section contains general and technical instructions that are to be
complied with
when performing the dismantling and reassembly tasks detailed in this
document.
Symbols, inserted throughout the maintenance text, precede the text of a
Danger,
Warning, Caution, Note and Parts List Reference. These symbols are used
in the fol-
lowing circumstances:
DANGER
Indicates an imminently hazardous situation which, if not avoided, will
result
in death or serious injury. This signal word is to be limited to the
most ex-
treme situation.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could
result
in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may
result
in minor or moderate injury. It may also be used to alert against unsafe
prac-
tices.
Caution
Note
12
Informs the user of the relevant Parts List where further details of
each com-
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2.2 General
2.2.1 Safety Precautions
The following general safety precautions apply to both dismantling and
reassembly
procedures. Throughout the maintenance text, where applicable, a specific
warning
and/or caution is inserted prior to the affected procedural step.
Maintenance personnel should also comply with the local/regional safety
require-
ments.
Prior to starting maintenance, ensure that the turbine and all interfacing
systems are
shut down, drained and made safe as detailed in the Operation Manual.
Ensure that the steam turbine is stationary, because - on single-shaft
units - even
with the clutch coupling disengaged, the possibility exists of inadvertent
engagement
of the coupling.
When handling thermal insulation mats, always wear approved face masks and
gloves.
When using cleaning solvents, always wear approved protective goggles,
gloves and
clothing.
When operating welding equipment or grinding machines, always wear approved
protective goggles, gloves and clothing. Ensure that fire prevention
procedures are
observed and all personnel not involved in these operations are clear of
the immedi-
ate area.
When using the special hydraulically operated tools, ensure that the
manufacturers
recommendations for the specific fastener are followed. Do not lean over
the tool
when pressure is applied.
When lifting heavy equipment:
� use only the approved lifting devices and operate them in accordance with
the
appropriate instructions
� ensure that the load is correctly secured
� Do not stand under suspended load
� ensure that all personnel not involved with the lifting operation are
kept clear of
the immediate area.
2.2.2 Standard Engineering Practices

Standard engineering practices, described in the following paragraphs,
should be fol-
lowed during all maintenance procedures. Knowledge of, and the correct use
of,
tools and equipment is assumed throughout.
To prevent housing deformation, loosen/tighten split-line fasteners in the
correct se-
quential order.
To prevent equipment (for example: instrumentation) against deformation or
damage
use suitable covers.
en HTGD 693 000 V0140 A

1381
To prevent ingress of foreign objects during dismantling, seal all

pipe/housing ori-
fices with the approved maintenance covers provided, see the instruction
manual
Tools according to the manufacturer. During reassembly, remove the blank
from a
sealed pipe/casing housing immediately prior to reconnection.
On reassembly, renew all O-rings, seal rings, gaskets, safety locking
plates and
spring washers that were removed during dismantling.
On reassembly, renew all fasteners that had a locking bead weld ground off
during
dismantling.
Do not rotate the turbine rotor shaft without activating the HP jacking-oil
system or
damage may be caused to the white metal linings of the journal bearings.
Measurements and checks of the turbine max axial bearing clearance only
with the
HP jacking-oil system activated.
Measurements and checks of the turbine blade clearances are to be performed
with-
out the HP jacking-oil system activated.
After shut-down, use the rotor turning gear system to rotate the turbine
rotor shaft
until the ST set has cooled to less than 150 �C. (302 �F). Failure to do
this could re-
sult in distortion of the turbine rotor shaft.
For fasteners not listed in the Test Certificates, use standard torque
loading prac-
tices.
2.2.3 Technical Knowledge Required

Extensive technical knowledge and experience is required by personnel
tasked with
the maintenance work.
Note
Only ALSTOM staff should do overhaul work.
All maintenance must be undertaken in accordance with the instructions

detailed in
the Operating and Maintenance Manuals.
Common site repairs require only the use of standard practices and basic
engineer-
ing knowledge.
All welding must be done only by technical staff possessing the valid
licences to per-
form such work. Where the performance or safety of the steam turbine is in
question,
consult with the ALSTOM service department.
ALSTOM assumes no liability for damage caused by defective maintenance work
or
by inadequate preventive maintenance programmes.
2.2.4 Replacement Parts

Serious damage can be incurred as a result of using replacement parts that
have not
been approved by ALSTOM. ALSTOM assumes no liability for damage caused by
the use of non-approved replacement parts.
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Always check which replacement parts will be required and ensure that all
replace-
ment parts are available before starting work.
Note
When ordering spare parts, only use the identification detailed in the
relevant Parts
List.
2.2.5 Tools and Lifting Devices

In some cases the maintenance tasks require the use of special tools and
lifting de-
vices. Where such tools and lifting devices are required, their use is
detailed in the
relevant text and highlighted both in text and on the appropriate figure by
the symbol.
Unless stated otherwise, return all jacking screws, guide bolts, taper pins
and ap-
proved maintenance covers to the relevant tool chest after each stage of
disman-
tling/reassembly.
Taper pins should always be inserted in the housing flanges before the
flanges are
brought together. When inserting a taper pin, it should be a tight fit.
Note
Exceptions from the above mentioned rule are mentioned in the maintenance
in-
structions.
ALSTOM denies any responsibility for damages caused by the use of
unsuitable or
damaged tools or hoisting equipment.
ALSTOM assumes no liability for damage incurred by the use of unsuitable or

dam-
aged tools and lifting devices.
2.2.6 Inspections and Checks

The maintenance text details the inspections and checks required during
disman-
tling/reassembly procedures and provides references to the relevant Test
Certifi-
cates.
2.2.7 Reassembly
All component parts being reassembled must:
� be clean, free of scale and solvent residues
� be fully functional
� have no cracks or mechanical damage
� have no excessive wear
Seal surfaces must be clean and free of cross-grooving and damage. If
necessary,
smooth the surfaces with an oil stone.
Immediately before reassembly, lubricate all threads, fits and contact
surfaces with
high-heat resistant lubricant. Refer to paragraph 2.4.
en HTGD 693 000 V0140 A

1383
Always reassemble components in their original positions, noting the

alignment iden-
tifications marked on them prior to dismantling.
Make sure that all bolted joints are tightened and secured in accordance
with the in-
structions, guidelines of the manufacturer, data sheets or test
certificates.
Caution
Do not use securing wires in the steam chambers or inside pipelines because
bro-
ken wires may damage machine parts. Use other securing methods.
2.2.8 Pipework
Seal the openings correctly and protect the flange and/or seal surfaces
from dam-
age.
Use only blanking flanges, blanking plugs, etc. to seal the openings. Never
block the
pipe lines with cleaning cloths or similar materials.
After the pipe lines and hoses have been cleaned and sealed, ensure that
they are
correctly identified and place them in a protected storage area.
Prior to reassembly, remove all blanks and check the pipeline for
cleanliness and
signs of damage.
2.3 Shutting down the turbine

Caution
The turning gear may only be switched off if the max. metal temperature is
less
than 150 �C. (302 �F).
In case of an emergency the turning gear may be switched off for a maximum
of 15
min after one day and 30 min after 2 days of turning gear operation,
provided that
the vacuum is broken and the gland steam system switched off.
The turning gear may be switched off, if required, for a longer period of
time (e.g.
overhauls) if the max. metal temperature is less than 200 �C. (392 �F). The
auxil-
iary lube oil pump can be switched off at that time as well.
Consult the Alstom Service Department on deviations. Non-fulfillment of
this re-
quirement may cause deformation of the turbine rotors and severe damage of
the
turbine components.
The following sub-paragraphs detail the tasks to be performed before

commencing
the dismantling procedures contained in the following sections.
2.3.1 Steam Temperature Distribution

Prior to shut down and at full load, measure and record the temperature
distribution
as detailed in the Operation Manual.
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2.3.2 Steam Turbine Shut Down and Isolation

The following actions are to be performed in accordance with the specific
shut down
and isolation procedures detailed in the Operation Manual:
� shut down the steam turbine
� allow the automatic rotor turning gear to operate until the highest steam
turbine
temperature is 150 �C. (302 �F) or less
� isolate the rotor turning gear system
� isolate the steam systems
� isolate all electrical systems.
2.3.3 Removal of Split-line Insulation Mats

Prior to the removal of the split-line insulation mats, check to ensure
that the identifi-
cation markings of the insulation mats are legible.
In accordance with the manufacturers instructions for the steam turbine
insulation
remove, as necessary for access, the split-line insulation mats. Examine
the insula-
tion mats and their fastenings for damage. Renew any damaged items prior to
reas-
sembly. Store the removed insulation items in a clean, dry protected area.
2.3.4 Removal of the Sound-proof Structure

For maintenance access, it is necessary to remove only those components of
the
sound-proof structure that are above the steam turbine.
In accordance with the manufacturers instructions remove the following
components
of the sound-proof structure:
� guard rails
� roof and wall panels
� associated roof and wall support structure.
Check all portions of the removed structure for damage (damaged items are
to be
renewed prior to reassembly) and store them in a protected area.
2.3.5 Pre-dismantling Visual Checks

Prior to commencing the dismantling procedures contained in Sections ,
visually ex-
amine:
� all lubrication, hydraulic and fuel-oil filters for signs of leaks and
damage
� all housing/casing split-lines, pipe lines and pipe joints for signs of
leaks and
damage
� all electrical cables for chafing, fraying and other damage.
en HTGD 693 000 V0140 A
1385
2.3.6 Inspections Prior to Dismantling

The following inspections are to be performed before commencing the
dismantling
procedures contained in the following Sections.
� Radial Position of Rotor
� Axial Bearing Clearance
� Expansion Sleeve Coupling
� Alignment of Shafts
� Casing Deflection
2.3.7 Dismantling Sequence

The maintenance instructions contain the dismantling procedure for the main
areas
of the steam turbine. Depending on the availability of personnel, there are
certain
dismantling tasks that can be performed simultaneously.
2.3.8 Reassembly Sequence

The maintenance instructions contain the reassembly procedures for the main
areas
of the steam turbine. Depending on the availability of personnel, there are
certain re-
assembly tasks that can be performed simultaneously.
2.3.9 Inspections After Reassembly

The following inspections are to be performed after the assembly of the
steam tur-
bine have been completed.
� Radial Position of Rotor
� Alignment of Shafts
� Screw Plug: Torque
� Expansion Sleeve Coupling
� Axial Bearing Clearance
� Radial Bearing Clearance
� Bolting, Coupling Cover
� Clearance of Oil Scraper,
� Pipelaying
2.4 Lubricating the components and parts

2.4.1 Lubricants for bladings
Use special grease 27 (Klueber HEL 46-450) for blade grooves in
circumferential di-
rection and special grease 18 (Molykote TP42) for fir-tree grooves.
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2.4.2 Lubricants for turbine parts

Use special grease 27 (Klueber HEL 46-450) in the following manner for all
other
turbine parts.
Immediately prior to component assembly, using a brush, apply a thin even
coat of
the relevant lubricant type as follows:
� expansion stud/sleeve/nut assemblies; lubricate the contact surface of
the nut,
upper face of the sleeve and all threads
� stud/nut assemblies; lubricate the contact surfaces of the nut and flange
and all
threads
� hexagon head screws and socket head screws; lubricate their contact
surfaces
and threads
� sliding surfaces in accordance with the instructions, guidelines of the
manufac-
turer, data sheets or test certificates
2.4.3 Lubricants for coupling

Coat the contact surfaces of coupling bolts and screws, nuts and sleeves as
well as
the coupling bores with MoS2 powder 1.
2.4.4 Reassembly of Journal and Thrust Bearings

Immediately prior to reassembly of the turbine rotor shaft journal bearings
and thrust
bearing, lubricate all bearing surfaces with clean lube oil.
2.4.5 Reassembly of Turbine and Bearing Housings
Caution
Do not let silicon-based or teflon-based materials get onto the turbine
Shaft, bear-
ings or any part of the lubrication system.
Silicon-based or teflon-based materials can cause contamination of the
lubrication
system.
2.4.6 Tightening Torques and Pre-stressing Forces

� For details of the tightening torques and pre-stressing forces for
hexagonal head
screws, hexagonal socket head screws, expansion studs, expansion bolts,
waisted hexagonal head screws and hexagonal socket head screws manufac-
tured from Steel guidelines are required in accordance with the details
given in
the data sheets.
en HTGD 693 000 V0140 A
1387
2.4.7 Special Maintenance Precautions
Caution
During maintenance, ensure that the rotor is only turned in working
direction.
Before commencing the removal of turbine top-half housings, supports and
jacks
must be installed as described in accordance with the instructions,
guidelines of the
manufacturer, data sheets or test certificates.
Once installed and locked, the jacks must remain undisturbed and locked
until the
top-half housing has been refitted and completely bolted in position.
Reference should be made to instruction manual 'Split-plane Flange Bolting;
Hy-
draulic Tightening of Expansion Bolts', in accordance with the
instructions, guide-
lines of the manufacturer, data sheets or test certificates
2.4.8 Test Certificates

Inspections and checks to be carried out in areas where defects are most
likely to
occur are detailed in the maintenance instructions.
Copies of the Test Certificates and Assessment Sheets are to be used to
record the
results of the inspections and checks. The completed forms are to be
forwarded to
the ALSTOM Service Department.
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CHAPTER 3
DISASSEMBLY PREPARATIONS
en HTGD 693 000 V0140 A 1389

3 DISASSEMBLY PREPARATIONS
Carry out the work described below in accordance with the shutting down and
isolat-
ing instructions of the operating manual.
3.1 Shutting down the turbine

Caution
The turning gear may only be switched off if the max. metal temperature is
less
than 150 �C. (302 �F).
In case of an emergency the turning gear may be switched off for a maximum
of 15
min after one day and 30 min after 2 days of turning gear operation,
provided that
the vacuum is broken and the gland steam system switched off.
The turning gear may be switched off, if required, for a longer period of
time (e.g.
overhauls) if the max. metal temperature is less than 200 �C. (392 �F). The
auxil-
iary lube oil pump can be switched off at that time as well.
Consult the Alstom Service Department on deviations. Non-fulfillment of
this re-
quirement may cause deformation of the turbine rotors and severe damage of
the
turbine components.
3.2 Sound-absorbing enclosure

3.2.1 Removing the sound-absorbing enclosure
Access to the turbine for carrying out maintenance work requires only
removal of
those parts of the sound-absorbing enclosure which are directly above and
beside
the turbine block to be serviced.
For this purpose follow exactly the manufacturer's instructions for
removing:
� the guard rails
� the roof and wall plates
� the pertinent roof and wall supporting parts.
Inspect all removed parts for damage and store them at a protected place
until re-
installation.
3.2.2 Re-installing the sound-absorbing enclosure

Follow the manufacturer's instructions when re-installing the enclosure.
Replace
damaged parts for safety reasons.
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3.3 Turbine insulation

3.3.1 Removing the insulation
Before removing the hard shell and the insulation, inspect visually the
surfaces and
connecting parts of the insulating mats and packages, also for possibly
existing
steam leakage.
Inspect the area of the bearing pedestals, especially for lube oil which
might have
entered.
Check the marking of re-usable insulation (mats or packages) and mark once
again,
if necessary.
Where access is necessary, remove the insulation in accordance with the
manufac-
turer's instructions and store it in a clean, dry and protected room until
re-installation.
Check the re-usable insulation and fastening parts for damage.
3.3.2 Re-installing the insulation

Follow the manufacturer's instructions when re-installing the insulation.
Replace damaged insulation or fastening parts.
Strictly follow the relevant drying and application instructions when
installing new or
partly new insulation.
Make sure that insulating mats which are fastened to the casing lower half
have par-
ticularly good contact.
Caution
The insulation material for austenitic steels may not contain any halogens
or halo-
genide salts because of the danger of stress corrosion cracking.
Cover the movable parts, for example in the area of the valves and
actuators, if a
new insulation has to be applied and clean the parts once again, if
necessary.
3.4 Isolating the auxiliary systems

Isolate the auxiliary systems according to the overhaul plans or according
to the in-
structions of the manufacturer.
Keep in service the auxiliary systems which are required for maintenance
such as
the jacking oil system or turning gear system and take them out of
operation tempo-
rarily for the required maintenance work.
Make sure when isolating the lube oil, control oil and hydraulic supply
systems that
the relevant pumps are out of operation and secured against unintended
switching-
on.
This applies particularly for all redundant components which are operated
and
switched via a direct current set.
en HTGD 693 000 V0140 A

1391
Ensure absolute cleanliness when opening and servicing such systems, even if
the
connections are open for a short time only.
Take out of operation the seal air system and secure it against unintended
starting.
Take out of operation the gland steam and auxiliary steam systems.
3.5 Providing the auxiliary means

Make available the spare parts in accordance with the spare part
recommendations.
Check the required tools for completeness, proper functioning and
operational readi-
ness and make them available.
Make available the test certificates and data sheets required for the
overhaul.
3.6 Sequence of disassembly

This document contains the instructions for disassembly and re-assembly of
the
main components of the turbine block up to lifting off and re-installing the
turbine ro-
tor.
Depending on the available personnel, some of the activities can be carried
out si-
multaneously.
Please refer to the relevant maintenance documents of the components or
systems
for disassembly of the subassemblies, mounted on the turbine.
These activities can also be carried out at the same time as the maintenance
work
on the turbine, if the appropriate personnel is available.
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CHAPTER 4
DISASSEMBLY OF THE THRUST BEARING PEDESTAL
en HTGD 693 000 V0140 A 1393

4 DISASSEMBLY OF THE THRUST BEARING PEDESTAL

The journal thrust bearing pedestal is located between the high pressure
(HP) tur-
bine and the generator.
4.1 General
12
For parts identification and ordering, refer to parts lists
MAD20
Caution
Do not let silicon-based or teflon-based materials get onto the turbine
Shaft, bear-
ings or any part of the lubrication system.
Silicon-based or teflon-based materials can cause contamination of the
lubrication
system.
4.2 Preparations
Disconnect all electric connections of the instrumentation and the
thermocouples at
the bearing pedestal upper part, and rotor turning gear.
Mark the connections for subsequent re-connection.
WARNING
Automatic re-start
Tag-out/Lock-out the pumps for generating the pressure in the system
to pre-
vent unexpected switching-on.
The pickups for measuring shaft vibration, phase angle and speed
measurements
must be removed before the disassembly.
Cover the absolute expansion measurement 7 to protect it against damage,
refer to
Fig. 4-3.
4.3 Blanking off the lube oil supply

Note
This is only required if the auxiliary oil system for feeding the
jacking oil pump must
be taken into operation.
This is necessary if during the maintenance work:
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� the couplings have to be dismantled

� the rotors have to be turned or shifted
� the bearing clearances have to be measured.
4.3.1 Removing the plug with orifice

Loosen the hexagon head bolts 10 at the plug 11 and pull out the plug 11 at
the eye-
bolt 5 using hoisting equipment, refer to Fig. 4-1.
Remove the bearing oil orifice 8 from the dismantled plug 11 and install
the blanking
plate 13 .
4.3.2 Re-installing the plug with orifice
Note
Mark at the outer side of the bearing pedestal that the blanking plate is
installed.
Fasten the original orifice to the eyebolt of the plug with orifice.
Lift-in the plug 11 and screw it to the bearing pedestal lower part 1 with
the hexagon
head bolts 10.
en HTGD 693 000 V0140 A

1395
4 5
10 6
9
3
13
11
7
12
BLNC0202_
A2465

1 Bearing pedestal, lower part 8 Orifice
2 Seal 9 Cylindrical pin
3 Flange 10 Hexagon head bolt
4 Hexagon head bolt 11 Plug
5 Eyebolt 12 Vibration
transmitter
6 Cylindrical pin 13 Blanking plate
7 Socket head screw
Fig. 4-1 Removing the plug with orifice
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4.4 Remove the coupling cover.

Loosen the hexagon head screws 2 in the coupling cover upper flange face and
split
plane, refer to Fig. 4-2.
Attach hoisting equipment and remove the coupling cover upper 4.
Support the lower coupling cover 1 and loosen the hexagon head screws 2 in
the
flange face, then remove the cover.
WARNING
Suspended Load
area.
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1397
BLNA0403_
2,3,5
A2464

1 Coupling cover 4 Coupling cover upper
2 Hexagon head screw 5 Hexagon head nut
3 Washer
Fig. 4-2 Removing the coupling cover
4.5 Removing the Instruments

4.5.1 Removing the shaft vibration transmitter
Disconnect the shaft vibration transmitters from the terminal box Unscrew
the shaft
vibration transmitters 3 from the bearing pedestal upper part and remove
completely
the shaft vibration transmitters, refer to Fig. 4-3.
4.5.2 Removing the Phase-Angle-Measurement

Disconnect the phase-angle-measurement from the terminal box Unscrew the
Phase-Angle-Measurement 2 from the bearing pedestal upper part and remove
completely the Phase-Angle-Measurement, refer to Fig. 4-3.
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4.5.3 Removing the Shaft Speed Measurement

Disconnect the shaft speed measurement from the terminal box Unscrew the
Shaft-
Speed-Measurement 1 from the bearing pedestal upper part and and remove
com-
pletely the Shaft-Speed-Measurement, refer to Fig. 4-3
1
2,3
8 5
6
7
4
BLNS0204_
A2462

1 Assembly speed sensor 5 Support
2 Phase angle measurement 6 Support
3 Shaft vibration measurement 7 Absolute expansion
measurement
4 Support 8 Casing vibration
measurement
Fig. 4-3 Arrangement of the instruments
en HTGD 693 000 V0140 A

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4.5.4 Blanking off the oil supply to the turning gear

Loosen the bolted joint 2 of the oil pipe 4 to the turning gear 1 in the
parting plane of
the bearing pedestal, refer to Fig. 4-4. Loosen and remove the screws
clamps and
locking plates of the oil pipe 4 and then remove the pipe.
Close off the oil pipes at the pressure side with cap 10 .
10
2 4
BLNJ0202_
A2466

1 Rotor turning gear 4 Oil pipe
2 Bolted joint 10 Pipe cap
Fig. 4-4 Blanking off the oil supply to the turning gear
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4.6 Lifting off the rotor turning gear

4.6.1 Preparation
Make sure that all electrical and hydraulic connections are disconnected.
Remove the turning gear cover 6 and attach the lifting eyes, refer to Fig.
4-5.
Note
Read the rotor turning gear type WDE6016 manual. HTGD
691 883
V9000
4.6.2 Lifting off the rotor turning gear

Attach the hoisting equipment 4 to the rotor turning gear 2, refer to Fig.
4-5.
Loosen and remove the hexagon head bolts 3 from the mounting flange.
Note
Two of the bolts are inside the turning gear housing the other bolts are
outside.
Slowly and carefully, lift off the turning gear from the pedestal housing.
Keep the rotor turning gear horizontal when lifting off.
WARNING
Suspended Load
Make sure that persons not involved in the procedure are out of the
danger
area.
Move the turning gear to a clean storage area and put it down onto stable
supports.
en HTGD 693 000 V0140 A

1401
6
3
4
5 2
1
801
BLNA0402_
A2467

1 Pedestal housing upper half 5 Lifting eye
2 Rotor turning gear 6 Cover
3 Hexagon socket head bolt 801 Taper pin
4 Hoisting equipment
Fig. 4-5 Lifting off the rotor turning gear
4.7 Lifting off the bearing pedestal upper part

Attach shackles to the upper part lifting lugs and connect to the hoisting
equipment
as shown on Fig. 4-6. Use chain hoists to make sure that the bearing cover
split line
stays horizontal when lifted.
Make sure that the load is correctly secured
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Check the horizontal split line between the bearing pedestal upper and
lower part for
signs of oil leakage.
4.7.1 Loosening the flange joint

Screw the jack screws 7 into the upper part 2, refer to Fig. 4-6.
Remove the taper pins 8 and put them in the tool cabinet.
Loosen the hexagon socket nuts 4 at the upper part in the parting plane of
the bear-
ing pedestal and remove them.
4.7.2 Lifting off the upper part
WARNING
Suspended Load
danger
area.
Screw the jack screws 7 against the bearing pedestal lower part 1 and lift
the up-
per part 2 by 1 - 2 mm, refer to Fig. 4-6.
Lift off carefully and vertically the bearing pedestal upper part 2 with
assembled turn-
ing gear. Do not damage the threads of the elongation studs 3 and the oil
shields 6
in the upper part and set down on suitable wooden blocks.
Use and arrange the tools according to Fig. 4-6. Keep the bearing pedestal
upper
part horizontal using the chain hoists.
Unscrew the elongation studs 3.
Cover the lube oil supplies in the parting plane to prevent unwanted
material from
getting into the lube oil system, use yellow adhesive tape so that it is
easily visible.
Note
Unscrew the jack screws from the upper part and put them in the tool
cabinet.
en HTGD 693 000 V0140 A

1403
5 9
4
8
6
2
FIG 04
7
3
BLNA0401_
A2463

1 Bearing pedestal lower part 6 Oil shield upper part
2 Bearing pedestal upper part 7 Jack screw
3 Elongation stud 8 Taper pin
4 Hexagon socket nut 9 Shackle
5 Cover
Fig. 4-6 Lifting off the upper part
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4.8 Check measurements and tests

4.8.1 Bearing pedestal upper part
Remove the oil shield upper parts 6 and check for damage and wear, refer to
Fig. 4-
6.
Check the drive pinion and the gear wheel of the turning gear for damage.
4.8.2 Bearing pedestal lower part

Measure and record the radial clearances of the oil shields. Test
certificate
HTGD 499
343
HTGD 667
267
Remove the oil shield lower parts 1 and check for damage and wear, refer to
Fig. 4-
7.
en HTGD 693 000 V0140 A

1405
4.8.3 Removing the shaft position monitor

Remove the hexagon head bolts of the transmitter holder 2 and remove it
com-
pletely, refer to Fig. 4-7
Measure the position of the rotor relative to the bearing pedes- Test
certificate
tal and record it in the test certificate. HTGD 667
274
Measure the clearances of the axial fixing system and record Test
certificate
the values in the test certificate. HTGD 667
275
1
FIG 06
BLNB0202_
A2457

1 Oil shield lower part 3 Hexagon head bolt
2 Shaft position monitor
Fig. 4-7 Removing the oil shield lower parts

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HTGD693011V9020 -
Turbine Block
4.8.4 Thermocouples bearing body

12
MAD21CT001, MAD21CT002, MAD21CT003, MAD21CT004, MAD21CT005,
MAD21CT006
4.8.5 Removing the thermocouples from the bearing body

Dismantle the cable clamps, and disconnect the thermocouples from the
terminal
box. Remove the thermocouples 3, 4 and 5 from the bearing body, refer to
Fig. 4-8.
Mark them with the KKS designations.
1
3
4
5
BLNS0203_
A2458

1 Cable clamps 4 Thermocouple radial
lower shell
2 Terminal box 5 Thermocouple axial
upper shell
3 Thermocouple axial upper shell
Fig. 4-8 Arrangement of the thermocouples
en HTGD 693 000 V0140 A

1407
4.9 Removing the thrust bearing, upper part

12
MAD21
4.9.1 Check measurements on the thrust bearing

Start the jacking oil system.
Check the axial clearance of the bearing by shifting the rotor Test
certificate
and record the values into the test certificate. HTGD
667 273
Take out of operation the jacking oil system.
4.9.2 Removing the thrust bearing, upper part

Loosen the hexagon head bolts 4 and taper pin 5 in the parting plane of
the bearing
according to Fig. 4-9 and remove them.
Install the tools and carefully lift off the thrust bearing upper part 3
using a hoisting
equipment.
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13
4
4
12
6
7,8
3
11
9,10
BLNL0202_
A2459

1 Bearing pedestal lower part 8 Set of pads
2 Thrust bearing, lower part 9 Spring ring
3 Thrust bearing, upper part 10 Set of pads
4 Hexagon head bolt 11 Locking plate
5 Taper pin 12 Countersunk screw
6 Locking washer 13 Eyebolt
7 Spring ring 14 Shackle
Fig. 4-9 Removing the thrust bearing upper part
en HTGD 693 000 V0140 A

1409
WARNING
Suspended Load
danger
area.
4.9.3 Removing the sets of pads from the thrust bearing

Lift off manually both spring ring upper parts 7 and 9 with the upper sets
of pads 8
and 10 according to Fig. 4-9.
Remove a locking plate 11 and a countersunk screw 12 from each side of the
thrust
bearing lower part 2.
Turn out both spring ring lower parts with the lower sets of pads from the
bearing
lower part 2 and lift them off manually.
Check the sets of pads for damage.
Note
Always replace thrust tilting pads as a complete set for each side of the
collar.
4.10 Removing the journal bearing, upper part

12
MAD21
4.10.1 Check measurements on the journal bearing
Note
For bearing clearance measurement, the rotor raising device has to be
installed
before removing the bearing.
To measure the radial clearance of the journal bearing attach a dial gauge
at the
bearing pedestal and set the feeler of the gauge to the highest point of
the turbine ro-
tor. Lift the rotor carefully until the journal bearing upper part rests
on the rotor.
1410 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
Read the difference at the dial gauge as clearance "V" and re- Test
certificate
cord the values on the test certificate. HTGD
667 273
4.10.2 Removing the journal bearing, upper part

Loosen and remove the socket head screws 3 at the journal bearing upper
part 2, re-
fer to Fig. 4-10.
Attach the tools and carefully lift off the journal bearing upper part 2
using hoisting
equipment.
5
2
BLNL0303_
A2460

1 Journal bearing, lower part 5 Locking pin
2 Journal bearing, upper part 6 Eyebolt
3 Socket head screw 7 Shackle
4 Cylindrical pin
Fig. 4-10 Removing the journal bearing upper part
en HTGD 693 000 V0140 A

1411
WARNING
Suspended Load
danger
area.
4.10.3 Installing the rotor raising device
Note
This is only required if the thrust/journal bearing is to be removed and
the HP/LP
rotor shaft is to stay in place.
Install the rotor raising device 3 and lift the rotor by 0.2 - 0.3 mm,
refer to Fig. 4-11.
Note
Monitor the lifting of the rotor with a dial gauge.
Do not rotate or move the rotor when it rests on the rotor raising device.
1412 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
1, 2
BLNW0302_
A2461

1 Bearing body lower part 3 Rotor raising
device
2 Journal bearing shell lower part
Fig. 4-11 Installing the rotor raising device
4.11 Removing the thrust / journal bearing lower parts

12
Refer to parts list and component description:
MAD21
Carefully rotate out the lower bearing parts from the bearing pedestel in
accordance
with the component description and lift it off with hoisting equipment.
en HTGD 693 000 V0140 A

1413
WARNING
Suspended Load
area.
1414 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 5
DISMANTLING OF THE EXPANSION SLEEVE COUPLING
en HTGD 693 000 V0140 A 1415

5 DISMANTLING OF THE COUPLING

The coupling, designed as an expansion sleeve coupling, is located
between the tur-
bine and Generator.
12
MAK21
Remark
Remove first four coupling bolts, staggered by approx. 90�, and tension
them provi-
sionally without expansion sleeves. This keeps parallel the coupling
flanges during
dismantling and facilitates the removal of the remaining coupling bolts.
5.1 Preparations
Bend back the locking rings 5 on both sides A and B of the coupling
according to Fig.
5-1. Side B shows the secured operating position, side A the bent-back
position of
the locking rings.

3 Coupling bolt 5 Locking ring
4 Countersunk nut 6 Expansion sleeve
Fig. 5-1 Bending back the locking rings
1416 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
5.2 Installing the tensioning devices

Install the carrier ring 9 with mandrel 18 , support ring 11 and tensioning
device
23 on side A according to Fig. 5-2. In order to facilitate subsequent
removal of the
hydraulic cylinder 12 , maintain a clearance of 1 to 2 mm between the
hydraulic cyl-
inder and the support ring 11 .

Fig. 5-2 Installing the tensioning devices
5.3 Loosening the coupling bolts

Build up a pressure of p3 + 5 MPa (max. p3 + 10 MPa) accord- Test
certificate
ing to the test certificate at connection C of the hydraulic cylin- HTGD
667 270
der 12 so that the countersunk nuts 4 can be loosened.
Loosen the countersunk nuts by 2 to 3 turns in order to achieve the gap "b"
of at
least 2 mm according to Fig. 5-2.
en HTGD 693 000 V0140 A

1417
WARNING
Ejected component
Incorrect disassembly procedure can cause the coupling bolts to be ejected
from the bores during the subsequent work and cause injury.
Do not remove the countersunk nuts completely until the coupling bolts
are
withdrawn from the taper in the sleeve.
Decrease the oil pressure and remove the devices.

Remove the screw plug 24, if provided, from the cone connections D of the
coupling
bolts 3.
Install the extension tube 21 according to Fig. 5-3.
Build up an oil pressure of p1 to p2 according to the test certifi- Test
certificate
cate at connection D so that the coupling bolts can be removed HTGD 667 270
axially from the expansion sleeves. The oil pressure at connec-
tion D shall not exceed p2 + 20 MPa.

4 Countersunk nut 21 Extension tube
5 Locking ring 24 Screw plug
Fig. 5-3 Installing the extension tube
1418 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
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If the press fit of the coupling bolts 3 and expansion sleeves 6 cannot be
loosened
this way, lower the oil pressure at connection D. The extension tube 21
remains
installed.
Install an additional hydraulic device on side B of the coupling according to
Fig. 5-4.
Build up again an oil pressure of p1 to p2 according to the test Test
certificate
certificate at connection D and pressurise simultaneously the HTGD 667
270
hydraulic cylinder 12 via connection C. The oil pressure at
conn. D shall not exceed p2 + 20 MPa.
Loosen the coupling bolts.
Note
During the entire loosening process the countersunk nuts of the coupling side
A
must remain on the coupling bolts, but loosened by 2 to 3 turns, gap "b", at
least 2
mm.

5 Locking ring 21 Extension tube
6 Expansion sleeve 23 Tensioning device
7 Tension bolt
Fig. 5-4 Loosening the expansion sleeves
Remove all parts and tools after unscrewing the four coupling bolts 3.
en HTGD 693 000 V0140 A

1419
5.4 Tensioning provisionally the coupling bolts

Re-install the four coupling bolts 3 and countersunk nuts 4 Test
certificate
without expansion sleeves and locking rings and tension them HTGD 667 270
provisionally with an oil pressure of p2 according to the test cer-
tificate at connection C using the hydraulic tensioning device
according to Fig. 5-5.

10 Face spanner
After attaining the oil pressure, tighten the countersunk nuts 4 with the
aid of the car-
rier ring 9 and the mandrel 18 .
5.5 Dismantling
5.5.1 Installing the tensioning devices
Note
Install the devices as described in paragraph 5.2.
1420 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Note
Loosen the countersunk nuts as described in paragraph 5.3.1.
Note
Loosen the expansion sleeves as described in paragraph 5.3.2.
5.5.4 Loosening the provisionally tensioned coupling bolts

Loosen the provisionally tensioned coupling bolts with the devices
installed accord-
ing to Fig. 5-6.

10 Face spanner
Fig. 5-6 Loosening the provisionally tensioned coupling bolts
5.5.5 Final work

Remove the tools and dismantle the coupling components. Store the tools in
the tool
cabinets.
Press the coupling out of the recess according to Fig. 5-7 using the jack
screws.
en HTGD 693 000 V0140 A

1421
Note
Take note to the possible axial displacement of the turbine ro- Test
certificate
tor relative to the casing. HTGD
667 257
Note
Required axial shifting out of coupling recess according to data Data
sheet
sheet. HTGD
667 269
For this purpose screw two diametrically opposite jack screws 22 into
the balanc-
ing holes of the coupling flanges.
Caution
Make sure that both rotors rest on their journal areas, auxiliary bearings
or rotor
lifting devices.

22 Jack screw
Fig. 5-7 Forcing the coupling flanges out of the recess
Remove again the jack screws, clean and store them in the tool cabinet.
5.6 Inspecting the coupling

5.6.1 Coupling components
Check all coupling bolts, countersunk nuts and expansion sleeves for seized
parts,
deformation or other damage.
Replace defective or damaged parts by new ones before re-assembly.
1422 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
5.6.2 Coupling flanges

a) Check the coupling flanges and the areas contacting the coupling
components in
the same manner.
Inspect these parts additionally for a correct protective coating.
If this protective coating is defective or no longer provided, proceed as
follows:
b) Clean the relevant surfaces and thoroughly degrease them with a solvent
such as
spirit.
c) Clean mechanically corroded surfaces using a wire brush or emery cloth.
Note
Do not use emery disks.
d) Remove completely corrosion pits at the undercuts. Local finish-grinding

and pol-
ishing for smoothening the transitions is permitted.
The surfaces must have a roughness of 1.6 m (N 7) after polishing.
5.6.3 Applying the corrosion inhibitor

Spray or spread a corrosion inhibitor with a thickness of at least 30 m on
the
cleaned surfaces of the coupling flanges.
Use Universalgrund GK 128, obtainable via the ALSTOM-Service Department, or
another product, which complies with the ALSTOM specification, as corrosion
inhibi-
tor.
en HTGD 693 000 V0140 A

1423
Blank Page
1424 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 6
DISASSEMBLY OF THE VALVES
en HTGD 693 000 V0140 A 1425

6 DISASSEMBLY OF THE VALVES

Fig. 6-1 shows the assembly situation of the live steam valve.

Fig. 6-1 Live steam valve assembly
1426 HTGD 693 000 V0140 A en

MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
6.1 Locking the swing arm support

12
MAA12BQ001
Lock the swing arm support with hexagon head bolts 510 and Data
sheet
hexagon nuts 511, refer to Fig. 6-2 and data sheet. HTGD
667 231
BNAA0101_

506 Belleville spring assembly 511 Hexagon nut
510 Hexagon head bolt 600 Valve housing
Fig. 6-2 Locking the swing arm support
6.2 Dismantling the stop valve actuator

12
MAA12AA001
en HTGD 693 000 V0140 A

1427
6.2.1 Preparations
Mark all electric connections at the stop valve actuator to permit
subsequent re-
assembly and disconnect them.
WARNING
Automatic re-start
Tag-out/Lock-out the pumps for generating the pressure in the safety
system to
WARNING
Pressurized oil system
Oil under pressure could cause injury
The shutoff valve at the bladder accumulator must be closed.
The drain valves of the hydraulic systems must be open.

Dismantle all hydraulic connections at the stop valve actuator.
Note
Be careful of escaping hydraulic fluid. Collect hydraulic fluid with
baffles and oil
pans.
1428 HTGD 693 000 V0140 A

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Block
6.2.2 Loosening the coupling

Bend up the locking plates 103 and loosen the hexagon head bolts 102. Move
the
coupling cover 101 towards the stop valve according to Fig. 6-3.

100 Stop valve actuator 103 Locking plate
101 Coupling cover 106 Actuator piston
102 Hexagon head bolt 201 Intermediate piece
Fig. 6-3 Loosening the coupling
en HTGD 693 000 V0140 A

1429
6.2.3 Dismantling the stop valve actuator

Attach the stop valve actuator 100 with ropes and chain hoist to the
hoisting equip-
ment according to Fig. 6-4.
Take up uniformly the actuator weight with the hoisting equipment and chain
hoist
and align it horizontally.
703 201
100
104, 105 201 104, 105 201
106 106
BTAA0302_

100 Stop valve actuator 106 Actuator piston
104 Socket head screw 201 Intermediate piece
105 Spring washer 703 Shackle
Fig. 6-4 Dismantling the stop valve actuator
Measure dimension X (120 mm).

Loosen very carefully and alternately the socket head screws 104.
1430 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
WARNING
High spring pressure
The Belleville spring assembly of the actuator is compressed and can
cause
injury
Make sure to release the pressure before removing the bolts
completely.
Loosen complete the socket head screws 104 with spring washers 105 and
remove
horizontally the stop valve actuator and put it in a safe area.
WARNING
Suspended Load
danger
area.

12
MAA12AA001
6.3.1 Check measurements before dismantling

Measure and record the valve stroke and fitting dimensions. Test
certificate
HTGD
667 205
en HTGD 693 000 V0140 A

1431
6.3.2 Removing the coupling from the valve spindle

Knock the rollpin 203 out of the valve spindle 218 according to Fig. 6-5.
Note
Use a back-up to prevent deformation of the valve spindle. Mark the
position of the
coupling nut for re-assembly.
206
203 103 102 201
202 101
218
204,205
BVAB0201_

101 Coupling cover 203 Rollpin
102 Hexagon head bolt 204 Hexagon head bolt
103 Locking plate 205 Locking plate
201 Intermediate piece 206 Shield plate, two-part
202 Coupling nut 218 Valve spindle
Fig. 6-5 Dismantling the coupling and heat shield
1432 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Unscrew the coupling nut 202 and lift off the coupling cover 101 with
hexagon head
bolts 102 and locking plates 103.
Attach the coupling cover 101 and locking plates 103 with hexagon head
bolts 102 to
the control valve actuator 100 to keep them safe.
6.3.3 Dismantling the heat shield

Loosen the hexagon head bolts 204 and locking plates 205 according to Fig.
6-5,
then remove the shield plates 206.
6.3.4 Dismantling the intermediate piece

Loosen the hexagon nuts 210 and the hexagon head bolts 211 according to
Fig. 6-6.
Unscrew the locking ring 212.
Unscrew the screw plugs 213 and secure the upper segments of the segment
ring
214 with locking screws 801 and washers 802 against dropping.
Attach the intermediate piece 201 to the hoisting equipment using ropes and
a chain
hoist.
Loosen the hexagon nuts 215, take up uniformly the weight of the
intermediate piece
201 with the chain hoist and hoisting equipment and keep it horizontal.
Unscrew the hexagon nuts 215 and force the intermediate piece 201 with jack
screws 822 out of the recess. Remove horizontally the intermediate piece
and put
it in a safe area.
WARNING
Suspended Load
danger
area.
en HTGD 693 000 V0140 A

1433
823
A
216 213
214
215
201 211 210 212
822
801
802
A
214
BVAB0202_

201 Intermediate piece 215 Hexagon nut
210 Hexagon nut 216 Elongation stud
211 Hexagon head bolt 801 Hexagon head
bolt
212 Lock ring 802 Washer
213 Screw plug 822 Jack screw
214 Segment ring 823 Shackle
Fig. 6-6 Dismantling the intermediate piece
6.3.5 Dismantling the clamping ring

Mount the jack plate 804 with clamping pieces 803 and hexagon nuts 215 ac-
cording to Fig. 6-7. Push the valve internals approx. 1 - 2 mm inside over
the clamp-
ing ring 217 using four jack screws 805 .
1434 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Remove the segment ring 214 and insert the support 807 . Withdraw the clamping
ring 217 with studs 808 and hexagon nuts 809 .
Remove the seal ring 220. If the seal ring shows excessive scale, remove it
together
with the lock.

200 Stop valve 802 Washer
214 Segment ring 803 Clamping piece
215 Hexagon nut 804 Jack plate
216 Elongation stud 805 Jack screw
217 Clamping ring 807 Support
219 Lock 808 Stud
220 Seal ring 809 Hexagon nut
801 Hexagon head bolt
Fig. 6-7 Dismantling the clamping ring
en HTGD 693 000 V0140 A

1435
6.3.6 Withdrawing the valve internals

Fasten the tools according to Fig. 6-8 to the stop valve 200 and pull the
lock 219 as
far as possible forward in the housing using studs 808 and nuts 809.
Remove the studs 808 and hexagon nuts 809 .

200 Stop valve 804 Jack plate
215 Hexagon nut 807 Support
216 Elongation stud 808 Stud
219 Lock 809 Hexagon nut
803 Clamping piece
Fig. 6-8 Withdrawing the valve internals
6.3.7 Arranging the disassembly tools

Push the spacer tube 810 over the valve spindle 218 according to Fig. 6-9
and fas-
ten it with coupling nut 202 in order to lock the valve spindle.
Screw the adapter piece 811 onto the lock 219 and install the support tube
812
with socket head screws 813 .
Mount the weight 814 with hoisting equipment on the support Data sheet
tube 812 according to the data sheet and secure it with a HTGD 667 232
hexagon head bolt 816 .
1436 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Note
Support provisionally the support tube in horizontal direction.
Attach the unit consisting of valve internals and tools to the Data sheet
hoisting equipment according to the data sheet using ropes. HTGD 667 232

200 Stop valve 811 Adapter piece
202 Coupling nut 812 Support tube
218 Valve spindle 813 Socket head screw
219 Lock 814 Weight
807 Support 815 Eyebolt
810 Spacer tube 816 Hexagon head bolt
Fig. 6-9 Arrangement of the tools
en HTGD 693 000 V0140 A

1437
6.3.8 Removing the valve internals

Make sure that the internals hang horizontally at the hoisting equipment
without
jamming in the valve housing. Unscrew the hexagon nuts 215 and remove the
clamping pieces 803 , refer to Fig. 6-8.
Remove the internals carefully in horizontal direction according to Fig. 6-
10 and put
them in a safe area.

811 Adapter piece 814 Weight
812 Support tube
Fig. 6-10 Removing the valve internals
WARNING
Suspended Load
danger
area.
Remove the weight 814 , support tube 812 and adapter piece 811 .
1438 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
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6.4 Dismantling the stop valve diffuser

6.4.1 Loosening the diffuser
Loosen the elongation bolts 221 from the diffuser 222 according to Fig. 6-
11 with a
six point socket 817 and remove them.

221 Elongation bolt 817 Six point socket
222 Diffuser
Fig. 6-11 Loosening the diffuser
Note
Make sure that foreign particles do not enter the steam inlet. Cover the
steam inlet
thoroughly.
en HTGD 693 000 V0140 A

1439
6.4.2 Jacking apart the diffuser

Jack apart the diffuser according to Fig. 6-12 using jack screws 821 and
a six point
socket 820 .

222 Diffuser 821 Jack screw
820 Six point socket
Fig. 6-12 Jacking apart the diffuser
1440 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
6.4.3 Mounting the disassembly tools

Insert the support tube 812 with hoisting equipment into the stop valve 200
accord-
ing to Fig. 6-13 and fasten it with socket head screws 819 and six point
socket
820 at the diffuser 222.
Push the weight 814 onto the support tube 812 using the Data
sheet
hoisting equipment and secure it with a hexagon head bolt HTGD 667
232
816 according to the data sheet.
Note
Keep the support tube and the valve internals horizontal.

200 Stop valve 816 Hexagon head bolt
222 Diffuser 818 Holder
812 Support tube 819 Socket head screw
813 Socket head screw 820 Six point socket
814 Weight 824 Cover
815 Eyebolt
Fig. 6-13 Mounting the tools
6.4.4 Removing the diffuser

Attach the tools and diffuser with ropes to the hoisting equip- Data
sheet
ment according to the data sheet. HTGD 667
232
en HTGD 693 000 V0140 A

1441
Make sure that the support tube hangs horizontally in the hoisting
equipment, re-
move the diffuser horizontally and put it in a safe area.
WARNING
Suspended Load
danger
area.
6.5 Disassembling the stop valve

Bring the dismantled valve internals into the horizontal position according
to Fig. 6-
14.
Dismantle the coupling nut 202 and the spacer tube 810 . Remove the valve
spin-
dle 218 with mounted valve head 229.
Loosen and remove the hexagon head bolts 223. Remove the guide bushing 225
and the two-part bushing 226 with the lock washers 227.
1442 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block

202 Coupling nut 228 Guide bushing
218 Valve spindle 229 Valve head
219 Lock 230 Insert
223 Hexagon head bolt 231 Weld ring
224 Locking plate 232 Cylindrical pin
225 Guide bushing 233 Steam strainer
assembly
226 Bushing, two-part 810 Spacer tube
227 Lock washer
Fig. 6-14 Removing the valve spindle and bushings
6.6 Dismantling the control valve actuator

12
MAA12AA011
6.6.1 Preparations
Mark all electric connections at the control valve actuator to permit
subsequent re-
assembly and disconnect them.
en HTGD 693 000 V0140 A

1443
WARNING
Automatic re-start
Tag-out/Lock-out the pumps for generating the pressure in the safety
system to
WARNING
Pressurized oil system
Oil under pressure could cause injury
The shutoff valve at the bladder accumulator must be closed.
The drain valves of the hydraulic systems must be open.

Dismantle all hydraulic connections at the control valve actuator.
Note
Be careful of escaping hydraulic fluid. Collect hydraulic fluid with baffles
and oil
pans.
1444 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
6.6.2 Loosening the coupling

Loosen the hexagon head bolts 302. Move the coupling sleeve 301 towards the
con-
trol valve, refer to Fig. 6-15.
306 401
300
302
301
401
BTAB0401_

300 Control valve actuator 306 Actuator piston
301 Coupling sleeve 401 Intermediate piece
Fig. 6-15 Loosening the coupling
en HTGD 693 000 V0140 A

1445
6.6.3 Dismantling the control valve actuator

Attach the control valve actuator 300 to the hoisting equipment according
to Fig. 6-
16 using ropes and a chain hoist.
Take up uniformly the weight of the actuator with the hoisting equipment
and chain
hoist and align it horizontally.
730 306 401
300
304,305 304,305
Y
306 306
401 401
BTAB0402_

Fig. 6-16 Dismantling the control valve actuator
Measure distance Y (120 mm).

Loosen very carefully and alternately the socket head screws 304.
1446 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
WARNING
The Belleville spring assembly of the actuator is compressed and can
cause
injury
Make sure to release the pressure before removing the bolts
completely.
Loosen complete the socket head screws 304 with spring washers 305 and
remove
the control valve actuator horizontally and place it in a safe area.
WARNING
Suspended Load
danger
area.

12
MAA12AA011
en HTGD 693 000 V0140 A

1447
6.7.1 Check measurements before dismantling

Measure and record the valve stroke and fitting dimensions. Test
certificate
HTGD
667 206
6.7.2 Removing the coupling from the valve spindle

Knock the rollpin 403 out of the valve spindle 418 according to Fig. 6-17.
403
402
418
BVAC0201_

301 Coupling sleeve 406 Shield plate, two-part
302 Hexagon head bolt 407 Distance sleeve
402 Coupling nut 408 Hexagon head bolt
403 Rollpin 409 Locking plate
404 Hexagon head bolt 418 Valve spindle
405 Locking plate
Fig. 6-17 Dismantling the coupling and heat shield
Note
position of the
Unscrew the coupling nut 402 and lift off the coupling sleeve 301 with
hexagon head
bolts 302.
1448 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Attach the coupling sleeve 301 with hexagon head bolts 302 to the control
valve ac-
tuator to keep them safe.
6.7.3 Dismantling the heat shield

Loosen the hexagon head bolts 408 to release the distance sleeve 407 refer
to Fig.
6-17.
Loosen the hexagon head bolts 404 and remove the shield plates 406.
6.7.4 Dismantling the intermediate piece

Use hexagon socket spanners 850 , 851 to losen the hexagon nuts 410 and the
hexagon head bolts 411, refer to Fig. 6-18. Unscrew the locking ring 412.
Unscrew the screw plugs 413 and secure the upper segments of the segment
ring
414 with locking screws 801 and washers 802 against dropping.
Attach the intermediate piece 401 to the hoisting equipment using ropes and
a chain
hoist.
Loosen the hexagon nuts 415, take up uniformly the weight of the
intermediate piece
401 with the chain hoist and hoisting equipment and keep it horizontal.
Unscrew the hexagon nuts 415 and force the intermediate piece 401 with jack
screws 822 out of the recess. Remove horizontally the intermediate piece
and put
it in a safe area.
WARNING
Suspended Load
danger
area.
en HTGD 693 000 V0140 A

1449
823
415,416 414
410,411
401 412
B
822 413
A
851
850
414
801
802
BVAC0202_

401 Intermediate piece 416 Elongation stud
410 Hexagon nut 801 Hexagon head bolt
411 Hexagon head bolt 802 Washer
412 Locking ring 822 Jack screw
413 Screw plug 823 Shackle
414 Segment ring 850 Socket spanner
415 Hexagon nut 851 Socket spanner
Fig. 6-18 Dismantling the intermediate piece
6.7.5 Dismantling the clamping ring

Mount the jack plate 834 with clamping pieces 803 , washers 833 and hexagon
nuts 415, refer to Fig. 6-19. Push the valve internals approx. 1 - 2 mm
inside over the
clamping ring 417 using four jack screws 835 .
1450 HTGD 693 000 V0140 A
en
MAA10/MAC10 - HTGD693011V9020 -
Block
Remove the segment ring 414 and insert the support 832 . Withdraw the clamping
ring 417 with studs 830 and hexagon nuts 831 .
Remove the seal ring 420. If the seal ring shows excessive scale, remove it
together
with the lock.

400 Control valve 802 Washer
414 Segment ring 803 Clamping piece
415 Hexagon nut 830 Stud
416 Elongation stud 831 Hexagon nut
417 Clamping ring 832 Support
419 Lock 833 Washer
420 Seal ring 834 Jack plate
Fig. 6-19 Dismantling the clamping ring
en HTGD 693 000 V0140 A

1451
6.7.6 Withdrawing the valve internals

Fasten the tools according to Fig. 6-20 to the control valve 400 and pull
the lock 419
as far forward as possible in the housing using studs 830 and nuts 831 .
Remove the studs 830 and hexagon nuts 831 .
A384

400 Control valve 830 Stud
415 Hexagon nut 831 Hexagon nut
416 Elongation stud 832 Support
419 Lock 833 Washer
803 Clamping piece 834 Jack plate
Fig. 6-20 Withdrawing the valve internals
6.7.7 Arranging the disassembly tools

Push the spacer tube 837 over the valve spindle 418 according to Fig. 6-21
and
fasten it with coupling nut 402 in order to lock the valve spindle.
Screw the adapter piece 838 onto the lock 419 and install the support tube
812
with socket head screws 839 to the adapter piece 838 .
Mount the weight 814 with hoisting equipment on the support Data sheet
tube 812 according to the data sheet and secure it with a HTGD 667 233
hexagon head bolt 816 .
1452 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Note
Attach the unit consisting of valve internals and tools to the Data
sheet
hoisting equipment according to the data sheet using ropes. HTGD
667 233
839 838 419

400
815
816
812
402 837 418

814
832
BVAC0205_

400 Control valve 815 Eyebolt
418 Valve spindle 832 Support
419 Lock 837 Spacer tube
812 Support tube 838 Adapter piece
814 Weight 839 Socket head screw
Fig. 6-21 Dismantling the valve internals
en HTGD 693 000 V0140 A

1453
6.7.8 Removing the valve internals

Make sure that the valve internals hang horizontally in the hoisting
equipment with-
out jamming in the valve housing. Unscrew the hexagon nuts 415 and remove
the
clamping pieces 803 , refer to Fig. 6-20.
Remove the internals carefully in the horizontal direction, refer to Fig.
6-22 and put
them in a safe area.
812
814 402 837 838
BVAC0206_

402 Coupling nut 837 Spacer tube
814 Weight
Fig. 6-22 Removing the valve internals
WARNING
Suspended Load
danger
area.
Dismantle the weight 814 , support tube 812 and spacer tube 837 .
1454 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
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6.8 Dismantling the control valve diffuser

6.8.1 Loosening the diffuser
Loosen the elongation bolts 421 from the diffuser 422 according to Fig. 6-
23 with a
six point socket 845 and remove them.

422 Diffuser
Fig. 6-23 Loosening the diffuser
en HTGD 693 000 V0140 A

1455
6.8.2 Jacking apart the diffuser

Jack apart the diffuser according to Fig. 6-24 using jack screws 846 and
a six point
socket 845 .
845 846
422
BVAC0208_
422 Diffuser 846 Jack screw
845 Six point socket
Fig. 6-24 Jacking apart the diffuser
6.8.3 Mounting the disassembly tools

Attach the holder 840 using socket head screws 813 to the support
tube 812 ,
refer to Fig. 6-25.
Insert the support tube 812 with the hoisting equipment in the control
valve 400
and fasten it to the diffuser 422. Fasten the socket head screws 841 with
the six
point socket 845 .
Push the weight 814 with the hoisting equipment onto the Data
sheet
support tube 812 and secure it with a hexagon head bolt HTGD 667
233
816 .
Note
1456 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block

422 Diffuser 816 Hexagon head bolt
812 Support tube 840 Holder
813 Socket head screw 841 Socket head screw
814 Weight 845 Six point socket
Fig. 6-25 Arrangement of the tools
6.8.4 Removing the diffuser

Attach the unit consisting of tools and diffuser with ropes to the Data
sheet
hoisting equipment according to the data sheet. HTGD
667 233
Make sure that the support tube hangs horizontally in the hoisting
equipment, re-
move the diffuser horizontally and put it in a safe area.
en HTGD 693 000 V0140 A

1457
WARNING
Suspended Load
danger
area.
6.9 Disassembling the control valve

Bring the dismantled valve internals into the horizontal position according
to Fig. 6-
26.
Dismantle the coupling nut 402 and spacer tube 837 . Unscrew and remove the
adapter piece 838 . Remove the valve spindle 418.
Loosen and remove the hexagon head bolts 423 and locking plates 424
Remove the guide bushing 425 and the two-part bushing 426 with the lock
washers
427.
1458 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
434
433
838 423, 424 426 427
402 837 418 425 419

432
421
BVAC0209_

402 Coupling nut 426 Bushing, two-
part
418 Valve spindle 427 Lock washer
419 Lock 432 Cylindrical
pin
421 Piston ring 433 Flow
equaliser
423 Hexagon Head bolt 434 Bolt
424 Lock plate 837 Spacer tube
425 Guide bushing 838 Adapter piece
Fig. 6-26 Dismantling the valve spindle and bushings
6.10 Disassembling the stop valve actuator

12
MAA12AA001
en HTGD 693 000 V0140 A

1459
6.10.1 Putting down the stop valve actuator

Attach the dismantled actuator 100 vertically to the hoisting equipment
according to
Fig. 6-27 and put it down on the wooden supports 704 .
WARNING
Suspended Load
danger
area.
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MAA10/MAC10 - HTGD693011V9020 -
Block

100 Stop valve actuator 704 Wooden support
703 Shackle
Fig. 6-27 Putting down the stop valve actuator
en HTGD 693 000 V0140 A

1461
6.10.2 Removing the cover

Dismantle the cover 108 with seal 120 according to Fig. 6-28.
Dismantle the plate 114 and remove the magnet ring 118.

100 Stop valve actuator 116 Spring washer
108 Cover 118 Magnet ring
109 Socket head screw 119 Stroke transducer
110 Spring washer 120 Seal
114 Plate 704 Wooden support
115 Socket head screw
Fig. 6-28 Dismantling the cover
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MAA10/MAC10 - HTGD693011V9020 -
Block
6.10.3 Relieving and removing the spring assembly.
WARNING
The Belleville spring assembly of the actuator is compressed and can cause
injury
Make sure to release the pressure before removing the bolts completely.
Mount the assembly flange 705 according to Fig. 6-29 on the actuator
piston 106
and screw the parts together with a socket head screw 707 .
en HTGD 693 000 V0140 A

1463

106 Actuator piston 705 Assembly flange
107 Belleville spring assembly 706 Eyebolt
121 Insert ring 707 Socket head screw
122 Spring stop 708 Jack screw
Fig. 6-29 Relieving the spring assembly
Compress the Belleville spring assembly 107 with the jack screws 708
so far that
the insert ring 121 can be removed.
Relieve completely the Belleville spring assembly so that the spring stop
122 can be
moved manually.
Dismantle completely the assembly flange 705 , lift off the spring stop 122
and lift
the actuator piston 106 with the Belleville spring assembly 107 out of the
actuator us-
ing the hoisting equipment.
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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
6.11 Disassembling the control valve actuator

12
MAA12AA011
6.11.1 Putting down the control valve actuator

Attach the dismantled actuator 300 according to Fig. 6-30 vertically to
the hoisting
equipment and put it down on the wooden supports 704 .
WARNING
Suspended Load
danger
area.
en HTGD 693 000 V0140 A

1465

300 Control valve actuator 704 Wooden support
703 Shackle
Fig. 6-30 Putting down the control valve actuator
1466 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
6.11.2 Removing the cover

Dismantle the cover 308 with seal 320 according to Fig. 6-31.
Dismantle the plate 314 and remove the magnet ring 318.

300 Control valve actuator 316 Spring washer
308 Cover 318 Mating disk
309 Socket head screw 319 Transmission rod
310 Spring washer 320 Seal
314 Plate 704 Wooden support
Fig. 6-31 Dismantling the cover
en HTGD 693 000 V0140 A

1467
6.11.3 Relieving and removing the spring assembly.
WARNING
The Belleville spring assembly of the actuator is compressed and can cause
injury
Make sure to release the pressure before removing the bolts completely.
Mount the assembly flange 705 according to Fig. 6-32 on the actuator
piston 306
and screw the two parts together with a socket head screw 707 .
1468 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block

306 Actuator piston 705 Assembly flange
307 Belleville spring assembly 706 Eyebolt
321 Insert ring 707 Socket head screw
322 Spring stop 708 Jack screw
Fig. 6-32 Relieving the spring assembly
Compress the Belleville spring assembly 307 with the jack screws 708 so
far that
the insert ring 321 can be removed.
Relieve completely the Belleville spring assembly so that the spring stop 322
can be
moved manually.
Dismantle completely the assembly flange 705 , lift off the spring stop 322
and lift
the actuator piston 306 with the Belleville spring assembly 307 out of the
actuator us-
ing the hoisting equipment.
en HTGD 693 000 V0140 A

1469
Blank Page
1470 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 7
DISASSEMBLY OF THE HP/LP TURBINE
en HTGD 693 000 V0140 A 1471

7 DISASSEMBLY OF THE HP/LP TURBINE

12
MAA10/MAC10
Preliminary remarks
Note
Inspect all parts removed from the turbine for damage and store them at
a dry and
safe area until re-assembly.
Clean the tools used, check their completeness and put them in the tool
cabinet.
7.1 Preparations
Note
Mark all electric connections for the thermocouples and instruments at
the turbine
bearing for re-assembly and disconnect them.
1472 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
7.1.1 Opening the outer casing

To permit access to the exhaust casing, loosen the hexagon head bolts 128
at the
outer casing upper half and remove the rupture diaphragm support 126 with
the rup-
ture diaphragm 129, refer to Fig. 7-1. Two identically arranged rupture
diaphragms
are provided at the condenser neck. Open the manhole 131 in the condenser
neck.
BGAX0301_
A2468

126 Rupture diaphragm support 129 Rupture diaphragm assembly
127 Seal 130 Condenser neck
128 Hexagon head bolt 131 Manhole
Fig. 7-1 Opening the outer casing
en HTGD 693 000 V0140 A

1473
7.1.2 Loosening the bolting of the expansion joint

Loosen the hexagon head bolts 136 and remove the 5-part cover 137, refer to
Fig. 7-
2.
Loosen the hexagon head screws 138 and remove the five upper cover flanges
135.
BGAX0201A

2 Outer casing upper half 137 Cover (5-part)
130 Condenser neck 138 Hexagon head screw
132 Expansion joint 139 Support plate
133 Super seal 140 Washer
134 Hexagon head screw 141 Hexagon nut
135 Cover flange (8-part) 142 Washer
136 Hexagon head bolt 150 Lockwasher
Fig. 7-2 Loosening the bolting of the expansion joint
1474 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
The expansion joint 132 is now removed from the outer casing upper half 2.
7.1.3 Loosening the water injection pipe

Loosen the union 145 to 147 at the water injection pipe, refer to Fig. 7-3.
Remove
the elbow 143 with the seals 144.

2 Outer casing upper half 145 Hexagon head bolt
143 Elbow 146 Washer
144 Seal 147 Hexagon nut
Fig. 7-3 Separating the pipes
en HTGD 693 000 V0140 A

1475
7.2 Check measurements before dismantling the outer casing

7.2.1 HP turbine
Unscrew the screw plugs 13 with seal rings 14 at the bottom of the outer
casing, re-
fer to Fig. 7-4.
13,14
BGAG0103_
13 Screw plug 14 Seal ring
Fig. 7-4 Preparing the measurement plane
Check the guide clearances and fixing elements refer to the Test
certificate
test certificate. HTGD
667 247
Check the radial and the axial position of the rotor in the outer Test
certificate
casing refer to the test certificate. HTGD
667 256
7.2.2 LP turbine
Check the relative rotor position in the LP blade carrier refer to Test
certificate
the test certificate. HTGD
667 260
Access is possible through the already removed rupture diaphragm and the
manhole
in the condenser neck.
1476 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
7.3 Dismantling the outer casing upper half

7.3.1 Supporting the HP turbine casing
Support the outer casing lower half 1 with jack screws 901 on the bearing
pedestal
lower part 100 refer to Fig. 7-5.
Place dial gauges 904 on both sides and lift the casing by 0.02 to 0.05
mm using
the jack screws.

1 Outer casing lower half 901 Jack screw
2 Outer casing upper half 904 Dial gauge with gauge
rack
100 Bearing pedestal lower part
Fig. 7-5 Supporting the turbine casing
en HTGD 693 000 V0140 A

1477
7.3.2 Loosening the parting flange bolts of the outer casing

Remove the locking wires 204 of the locking screws 203 at the shaft seals
201 and
202 and loosen the locking screws by approx. 2 to 3 turns, refer to Fig. 7-
6. Remove
the locking screws at the upper half 202.
Remove the taper pins 903 and 907 , refer to Fig. 7-7.
Loosen and remove the socket head screws 121, refer to Fig. 7-6.
1478 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
121
4,7,11,12
13,850
202
107,108,109, 1 105,108,109,
110,123,850 110,123,850
203
104,108,109,
110,123,850
109,110,111,
204 112,123,850
201
BEAB0101_

1 Outer casing lower half 109 Nut
2 Outer casing upper half 110 Cover
4 Elongation stud 111 Elongation bolt
7 Nut 112 Expansion sleeve
11 Support ring 121 Socket head screw
12 Cover 123 Hexagon head bolt
13 Hexagon head bolt 201 Shaft seal lower
part
104 Elongation stud 202 Shaft seal upper
part
105 Elongation stud 203 Hexagon head bolt
107 Elongation stud 204 Locking wire
108 Support ring 850 Bolt tensioning
device
Fig. 7-6 Loosening the parting flange bolts

en HTGD 693 000 V0140 A
1479
Loosen the flange joints 104, 105, 107 to 112 and 123 using Test
certificate
the bolt tensioning device 850 , refer to the test certificate. HTGD 667
235
HTGD 667
236
Loosen the flange joints 4, 7, and 11 to 123 using the bolt ten- Test
certificate
sioning device 850 , refer to the test certificate. HTGD 667
235
HTGD 667
236
Use the hoisting equipment for positioning the bolt tensioning cylinders.
WARNING
Suspended Load
danger
area.
WARNING
Pressure hazard
Incorrect use of pressurised tools can cause serious injuries.
Do not lean or bend over pressurised tools.
danger
area.
Make sure to correctly follow the local and OEM (Original Equipment
Manufac-
ture) regulations.
Note
Carefully follow the instruction "Hydraulic stretching of elongation bolts"
when loos-
ing the elongation bolts. Take note of the tool manufacturers instructions.
7.3.3 Lifting off the outer casing upper half

Screw two guide bolts 908 at diagonally opposite positions into the outer
casing
lower half 1, refer to Fig. 7-7.
1480 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Lift uniformly the outer casing upper half 2 by 3 to 5 mm using the jack
screws 902
and 906 .
Attach the hoisting equipment to the outer casing upper half 2, Data sheet
refer to Fig. 7-7 and the data sheet "Disposition of slings". HTGD 667
271
1BSE 501
724
902
906
907
902
903 907 906
902
903
902
908
908
1
BEAB0102_

1 Outer casing lower half 903 Taper pin
2 Outer casing upper half 906 Jack screw
3 Turbine rotor 907 Taper pin
902 Jack screw 908 Guide bolt
Fig. 7-7 Lifting off the outer casing upper half

en HTGD 693 000 V0140 A
1481
Note
Keep the casing horizontal when lifting it off. Make sure that the guide
bolts move
freely in the bores.
WARNING
Suspended Load
danger
area.
7.4 Check measurements before dismantling the inner casing

Check the possible axial displacement of the turbine rotor rela- Test
certificate
tive to the inner casing, refer to the test certificate. HTGD 667
257
7.4.1 HP turbine
Check the radial and the axial position of the turbine rotor in Test
certificate
the inner casing, refer to the test certificate. HTGD 667
255
7.4.2 LP turbine
certificate
the LP blade carrier, refer to the test certificate. HTGD 667
260
7.5 Dismantling the inner casing upper half

7.5.1 Loosening the parting flange bolts of the inner casing
Loosen the flange joints 53 to 59 using the bolt tensioning de- Test
certificate
vice 850 , refer to Fig. 7-8 and the test certificate. HTGD 667
237
Use the hoisting equipment for positioning the bolt tensioning cylinders.
Screw two guide bolts 914 at diagonally opposite positions into the
inner casing
lower half 51.
1482 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Suspended Load
area.
WARNING
Pressure hazard
area.
Make sure to correctly follow the local and OEM (Original Equipment Manufac-
ture) regulations.
Note
when loos-
en HTGD 693 000 V0140 A

1483
914 53,56
54,57 58,850
59,850
912
913
912
52
51
914
BEAD0101_

51 Inner casing lower half 58 Support ring
52 Inner casing upper half 59 Support ring
53 Elongation stud 850 Bolt tensioning
device
54 Elongation stud 912 Jack screw
56 Nut 913 Taper pin (not
inserted)
57 Nut 914 Guide bolt
Fig. 7-8 Loosening the parting flange bolts of the inner casing
7.5.2 Lifting off the HP inner casing upper half

Lift the inner casing upper half 52 by 2 to 3 mm using four jack screws 912
, refer to
Fig. 7-8.
1484 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Attach the hoisting equipment to the inner casing upper half Data
sheet
52, refer to Fig. 7-8 and the data sheet "Disposition of slings". HTGD
667 271
1BSE
501 724
Note
bolts move
WARNING
Suspended Load
danger
area.
7.5.3 Loosening the parting flange bolts of the LP blade carrier

Loosen the flange joints 153 to 155 using the bolt tensioning Test
certificate
device 850 , refer to Fig. 7-9 and the test certificate. HTGD
667 238
Use the hoisting equipment for positioning the tensioning cylinders.
WARNING
Suspended Load
danger
area.
en HTGD 693 000 V0140 A

1485
WARNING
Pressure hazard
area.
Manufac-
ture) regulations.
Note
when loos-
Screw two guide bolts 917 diagonally opposite into the blade carrier
lower part
151.
1486 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
152
917
154, 850
155
153
916
915
152
A
A
918
916
917
151
917
BEAD0102_

151 Blade carrier lower part 850 Bolt tensioning
device
152 Blade carrier upper part 915 Jack screw
153 Elongation stud 916 Taper pin (not
inserted)
155 Support ring 918 Shackle
Fig. 7-9 Loosening the parting flange bolts of the LP blade carrier
7.5.4 Lifting off the LP blade carrier upper part

Lift the inner casing upper part 152 by 2 to 3 mm using four jack screws
915 , refer
to Fig. 7-9.
en HTGD 693 000 V0140 A
1487
Attach the inner casing upper part 152 to the hoisting equip- Data sheet
ment, refer to Fig. 7-9 and the data sheet "Disposition of HTGD 667
271
slings". 1BSE 501
724
Note
bolts move
WARNING
Suspended Load
area.
1488 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
7.6 Dismantling the HP shaft seal

Bring the shaft seal 201, 202 again into the operating position by tightening
the lock-
ing screws 203 in the lower half.

201 Shaft seal lower part 905 Taper pin (not inserted)
202 Shaft seal upper part 908 Jack screw
203 Locking screw 815 Shackle
Fig. 7-10 Dismantling the shaft seal upper part
Loosen and remove the socket head screws 205 at the parting flange, refer to
Fig. 7-
10.
Lift the upper part 202 by 2 to 3 mm using the jack screws 908 .
Lift off carefully the shaft seal upper part 202 with shackle and ropes using
the hoist-
ing equipment.
en HTGD 693 000 V0140 A

1489
Caution
Lift off the shaft seal upper part vertically and keep the joint faces
horizontal to pre-
vent damage to the sealing elements of the shaft seal.
WARNING
Suspended Load
danger
area.
7.7 Dismantling the enclosure and the LP shaft seal

7.7.1 Loosening the parting flange bolts of the enclosure
Attach the hoisting equipment to the cover 191, refer to Fig. 7-11
Loosen the hexagon head bolts 190 and remove the cover 191, refer to Fig.
7-11.
Loosen the hexagon head bolts 117 on both sides of the enclosure and remove
the
covers 116, refer to Fig. 7-11.
Loosen and remove the socket head screws 416 with the washers 417 at the
shaft
seal upper part 402 through the openings in the enclosure.
Loosen and remove also the socket head screws 121 in the parting plane in
the en-
closure interior through these openings.
Measure and record the radial clearance of the oil shield upper Test
certificate
part 169. HTGD
499 343
HTGD
667 267
Loosen and remove all socket head screws 121 in the parting plane on the
outside of
the enclosure.
Lift the enclosure 102 by 3 to 5 mm using four jack screws 906 .
Attach the hoisting equipment to the enclosure, refer to Fig. 7-11.
1490 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Note
Lift off the enclosure exactly vertically in horizontal position. Make sure
that all bolts
in the enclosure interior have been loosened and removed.

102 Bearing casing enclosure 402 Shaft seal upper part
116 Cover 416 Socket head screw
121 Socket head screw 906 Jack screw
169 Oil shield upper part 907 Taper pin (not inserted)
190 Hexagon head bolt 815 Shackle
191 Cover
Fig. 7-11 Loosening the parting flange bolts of the enclosure
en HTGD 693 000 V0140 A

1491
WARNING
Suspended Load
danger
area.
7.7.2 Dismantling the instruments in the bearing casing
Note
Mark all electric connections for the thermocouples and instruments at the
turbine
Remove the differential expansion transmitter 182 with holder, refer to

Fig. 7-12.
Remove both rotor vibration pick-ups 183 with holders.
Dismantle the thermocouples 181 from the journal bearing lower part 171.
1492 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
182 172 103
3 170 181 171
183 183
BFAS0202_
3 Turbine rotor 172 Journal bearing upper
part
103 Bearing bracket 181 Thermocouple
170 Oil shield lower part 182 Differential expansion
transmitter
171 Journal bearing lower part 183 Rotor vibration pick-up
Fig. 7-12 Dismantling the instruments
en HTGD 693 000 V0140 A

1493
7.7.3 Dismantling the LP shaft seal upper part

Loosen and remove the socket head screws 405 at the parting flange, refer
to Fig. 7-
13.
Lift off carefully the shaft seal upper part 402 with shackle 815 and
ropes using the
hoisting equipment.
905
815
405
402
401
BGAC0202_

401 Shaft seal lower part 815 Shackle
402 Shaft seal upper part 905 Taper pin (not
inserted)
Fig. 7-13 Dismantling the shaft seal upper part
1494 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
Caution
Lift off the shaft seal upper part vertically and keep the joint faces
horizontal to pre-
WARNING
Suspended Load
danger
area.
7.8 Dismantling the journal bearing

7.8.1 Dismantling the bearing bracket
12
For parts identification and ordering, refer to parts lists
MAC10, MAD51
Loosen the bolted joint 107 and 109 of the bearing bracket us-
Data sheet
ing the bolt tensioning device 850 , refer to Fig. 7-14 and
HTGD 630 147
document.
Use the hoisting equipment for positioning the tensioning cylinder.
en HTGD 693 000 V0140 A

1495
WARNING
Suspended Load
area.
Note
when loos-
1496 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
816
115
815
817
107
103
109
BEAL0101_

103 Bearing bracket 815 Shackle
107 Cylindrical bolt 816 Eyebolt
109 Support ring 817 Eyebolt
115 Cylindrical bolt 850 Bolt tensioning device
Fig. 7-14 Dismantling the bearing bracket
Attach the hoisting equipment to the eyebolt 816 and Pull out the
cylindrical bolt
115.
Lift off the bearing bracket 103, refer to Fig. 7-14.
en HTGD 693 000 V0140 A

1497
WARNING
Suspended Load
area.
1498 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
7.8.2 Dismantling the journal bearing upper part

Loosen and remove the socket head screws 173 in the parting plane of the
journal
bearing, refer to Fig. 7-15.
Lift off carefully the journal bearing upper part 172 with the hoisting
equipment.

170 Oil shield lower part 174 Cylindrical pin
171 Journal bearing lower part 175 Locking pin
172 Journal bearing upper part 815 Shackle
173 Socket head screw 816 Eyebolt
Fig. 7-15 Dismantling the journal bearing upper part
en HTGD 693 000 V0140 A

1499
WARNING
Suspended Load
danger
area.
Measure and record the radial clearance of the oil shield lower Test
certificate
part. HTGD 499
343
HTGD 667
267
Remove the oil shield lower part 170.
Note
This is only required if the journal bearing lower part must be removed
without lift-
ing out the turbine rotor.
1500 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
7.8.3 Dismantling the journal bearing lower part

refer to Fig. 7-
16.
Note
This is only required if the turbine rotor is not going to be lifted out.
902
171
BGAW0301_
A2131

171 Journal bearing lower part 902 Rotor raising device
Note
Turn the journal bearing lower part 171 carefully out of the bearing casing
and lift it
off with the hoisting equipment.
7.9 Check measurements before removing the rotor

Precondition
Note
The turbine rotor is in operating position.
en HTGD 693 000 V0140 A

1501
certificate
the inner casing refer to the test certificate. HTGD
667 255
certificate
the outer casing refer to the test certificate. HTGD
667 256
Check the axial displacement possibility of the turbine rotor Test

certificate
relative to the inner casing refer to the test certificate. HTGD
667 257
Check the radial and axial clearances of the stationary and the Test
certificate
rotating blading refer to the test certificate. 1BSE
001 637
Check the radial and axial clearances of the balance piston Test
certificate
refer to the test certificate. 1BSE
501 727
Check the radial and axial clearances of the HP shaft seal refer Test
certificate
to the test certificate. 1BSE 501
726
Check the radial clearances of the LP shaft seal refer to the Test
certificate
667 244
certificate
the LP blade carrier refer to the test certificate. HTGD
667 260
Check the gear drive of the main lube oil pump for damage or wear.
7.10 Lifting out the turbine rotor

Attach the turbine rotor 3 to the hoisting equipment using the Test
certificate
rotor lifting device 800 , refer to Fig. 7-17 and the data sheet HTGD
667 271
"Disposition of slings". 1BSE
501 724
Slightly lift the turbine rotor 3 and check the horizontal position.
Caution
Keep the rotor horizontal and monitor it with a precision water level to
prevent
damage to the blading and sealing elements. Re-adjust the rotor lifting
device, if
necessary, to ensure the horizontal position.
Lift out the turbine rotor 3 carefully and vertically, refer to Fig. 7-17.
Caution
The rotor must not jam during lifting off. It must always be possible to
move it
slightly. Place the rotor on the prepared assembly supports. The support
surfaces
must be protected.
1502 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
800
401
201
151
1 51
BEAB0103_

1 Outer casing lower half 201 HP shaft seal lower
part
3 Turbine rotor 401 LP shaft seal lower
part
51 HP Inner casing lower half 800 Rotor lifting device
151 LP Blade carrier lower part
Fig. 7-17 Lifting out the rotor
en HTGD 693 000 V0140 A

1503
WARNING
Suspended Load
area.
1504 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 8
MAINTENANCE
en HTGD 693 000 V0140 A 1505

8 MAINTENANCE
8.1 General recommendations

8.1.1 Checks and tests
Inspect all components visually and in accordance with the overhaul
recommenda-
tions and specified data of the test certificates and replace the parts, if
necessary for
reasons of operational safety.
Caution
This applies to all components, but especially to those which are heavily
stressed
during operation and have an effective or equivalent life expectancy in
operating
hours.
8.1.2 Cleaning the components

Clean thoroughly all dismantled or still installed components which show
visible
signs of wear, deposits, scale or stress and check their re-usability.
This applies particularly to:
� Screw threads, contact surfaces of nuts, bolt heads, expansion sleeves
and sup-
port rings
� Joint and sealing surfaces of casings and flanges
� Sliding surfaces, fits and adjusting elements.
8.1.3 Marking the dismantled components

Mark all components with their location code and store them at a safe and
dry place
until re-installation.
8.1.4 Replacing components

Replace principally all dismantled non-metallic sliding and guiding
elements, seals
and O-ring seals.
Replace also all pipe unions, metallic ring or crimp seals at particularly
exposed loca-
tions or if subjected to high operating pressures.
8.1.5 Tools
Check the tools, to be used during re-assembly, for completeness and
operational
readiness.
8.1.6 Test certificates

Make available the test certificates required for re-assembly.
1506 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
8.2 Bearing pedestals and turbine bearings

8.2.1 Foundation bolts
12
MA HA903
Check the pre-tension of the foundation bolts at the intervals Test

certificate
mentioned in the test certificate and enter the value. HTGD
667 259
8.2.2 Bearing pedestals

12
MAD20, MAD50
Check the joint and sealing surfaces of the casings for upsets and
grooves.
Check the sliding elements, guide keys and hold-down devices for wear,
pitting and
other damage.
Note
Dress with an oil stone, if necessary.
Check the oil shields at the rotor penetrations, re-machine them, if

necessary, or re-
place them by new shields.
Note
Keep all parts very clean in the oil chamber of the bearing pedestals.
Cover all
open bearing pedestals with clean tarpaulins, especially if work on the
pedestals is
finished.
Remove all tools before re-assembly.
8.2.3 Turbine bearings

12
MAD21, MAD51
Inspect particularly thoroughly the bearings.

� Check the bearing metal for cracks and defective adhesion.
en HTGD 693 000 V0140 A
1507
� Check the contact pattern of the bearing shells and load-carrying and
thrust pads.
� Inspect the adjusting plates.
� Check the jacking oil supply for impurities.
� Check the metal temperature measurement of the thermocouples.
� Smoothen thoroughly all scratches in the surface areas of the load-
carrying and
thrust pads of the bearings.
� Smoothen thoroughly the journal and thrust bearing sections of the
turbine rotor.
Note
Check whether the position of the turbine rotor in the bearing pedestal
has
changed because bearing parts have been dismantled or replaced or the
complete
bearing has been exchanged.
8.3 Valves and actuators

12
MAA12AA001, MAA12AA011
8.3.1 Valves
Check the valve spindles and guide bushings for:
� Wear
� Friction marks
� Surface condition
� Concentric run of the valve spindles
� Cracks in the valve spindles and diffusers
Smoothen all friction marks.
� Replace the components in case of heavy wear.
� Inspect the valve seats and lap them again, if necessary.
Check the steam strainers.
8.3.2 Actuators
Check all movable parts for wear and friction marks:
� Actuator piston and piston rod
� Belleville springs for cracks
1508 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
� Check valves for proper functioning.

Smoothen all friction marks. Replace the components in case of heavy
wear.
� Replace the O-ring seals, sealing and guiding elements.
� Check the functioning of the proximity switches and stroke
transmitters.
8.4 Turbine
12
MAA10
Caution
All adjustments of the inner and outer casings, the radial and axial
positions of the
rotor in the casings may only be changed by qualified personnel.
8.4.1 Visual checks

Carry out at least the following checks on the turbine components:
� Seal strips and seal rings for wear and rubbing marks
� Seal segments for free mobility and compression springs for pre-
tension
� Steam duct rings for wear and proper functioning
� Casing parts for erosion and cavitation
� Exposed components for stress corrosion cracking
� Guiding, sliding and adjusting elements for wear.
Note
Carry out a dye test with magnetic particles to detect cracks in the
machine parts.
This test is particularly important in the coupling section of the
turbine rotor.
8.4.2 Cleaning the machine parts

If the visual checks show deposits which require thorough cleaning of
the machine,
follow the instructions for removing salt and silica deposits in steam
turbines.
It is recommended to coordinate these activities with the ALSTOM Service
Depart-
ment.
8.4.3 Turbine instruments

Check the functioning of the startup probe and thermocouples.
en HTGD 693 000 V0140 A
1509
12
MAA10CT005, MAA10CT010, MAC10CT010
8.4.4 Replacing machine parts

Replace the components in case of heavy wear or malfunctioning.
Caution
Replace the elongation bolts with recorded pre-stress, which are exposed
to high
stress and temperatures above 420� C in operation, after 150'000
operating hours.
See the relevant remarks in the test certificates.
8.4.5 Re-assembly recommendations

� Secure all bolts in the steam chamber.
� Remove all tools before re-assembly.
8.5 Blading
12
MAA10HA410, MAA10HB410, MAC10HA420, MAC10HB420
Note
Deposits cause a decrease in efficiency and may endanger the operational
reliabil-
ity of the turbine.
8.5.1 Visual checks

Carry out at least the following checks on the turbine blading:
� Seal strips and seal rings for wear and rubbing marks
� Blading parts for deposits, erosion and cavitation
� Components for stress corrosion cracking
� Stationary and rotating blading for cracks and proper condition.
Note
Carry out a dye test with magnetic particles to detect cracks in the
machine parts.
This test is particularly important in the coupling section of the
turbine rotor.
1510 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
8.5.2 Cleaning the blading

If the visual checks show deposits which require thorough cleaning of the
blading,
follow the instructions for removing salt and silica deposits in steam
turbines.
Thorough cleaning is particularly important if the blading has to be
subjected to a dye
penetrant test with magnetic particles.
In this case the specific work instructions have to be ordered from the
Service De-
partment. The relevant activities have to be co-ordinated with and carried
out by the
ALSTOM Service Department.
8.5.3 Replacing blading parts
Note
Only ALSTOM personnel are authorized to carry out maintenance work on the
blading.
en HTGD 693 000 V0140 A

1511
Blank Page
1512 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 9
RE-ASSEMBLY OF THE
HP/LP TURBINE
en HTGD 693 000 V0140 A 1513

9 RE-ASSEMBLY OF THE HP/LP TURBINE

12
MAA10/MAC10
9.1 Starting point

The bearing pedestals are ready for re-assembly of the turbine.
Caution
Make sure that the radial and axial positions of the turbine bearings
relative to the
turbine are correctly adjusted. Check this even if the positions were
not changed.
Note
Lubricate slightly the bearing surfaces of the turbine rotor in the
region of the jour-
nal bearing with lube oil. Ensure absolute cleanliness.
9.1.2 Turbine
The turbine is ready for re-installing the turbine rotor.
Caution
Make sure that the radial and axial positions of the inner casing lower
half are cor-
rectly adjusted. Check this even if the positions were not changed.
Note
Lubricate slightly the bearing surfaces of the turbine rotor in the
region of the jour-
nal bearing with lube oil. Ensure absolute cleanliness.
9.2 Lifting into place the turbine rotor

Align the parting plane of the turbine casing refer to the test
Test certificate
certificate and record the actual values.
HTGD 667 240
9.2.1 Installing the lifting device

Attach the turbine rotor 3 to the hoisting equipment using the
Data sheet
lifting device 800 refer to the data sheet "Disposition of
HTGD 667 271
slings".
1BSE 501 724
1514 HTGD 693 000 V0140 A
en
MAA10/MAC10 - HTGD693011V9020 -
Block
Lift slightly the rotor and check the horizontal position. If necessary,
lift it higher on
the heavier side.
Caution
Keep the rotor horizontal and monitor it with a precision water level to
prevent
damage to the blading and sealing elements. Re-adjust the rotor lifting
device, if
necessary, to ensure the horizontal position.
9.2.2 Lifting into place the rotor

Lift the rotor and align it axially exactly with the turbine axis using the
hoisting
equipment, refer to Fig. 9-1.
Lower the rotor carefully and exactly vertically into the inner casing
lower half 51 and
blade carrier lower part 151.
Caution
The rotor must not jam during lowering. It must always be possible to move
the ro-
tor a small distance. Monitor the installation of the rotor in the inner
casing on both
sides. Rubbing of the sealing elements and blading is not permitted.
Note
Check the horizontal position of the rotor during lifting with a precision
water level
and keep it horizontal to prevent damage to the blades and shaft seals.
en HTGD 693 000 V0140 A

1515
800
401
201
151
1 51
BEAB0103_

1 Outer casing lower half 201 HP shaft seal lower
part
3 Turbine rotor 401 LP shaft seal lower
part
51 HP Inner casing lower half 800 Rotor lifting
device
151 LP Blade carrier lower part
Fig. 9-1 Lifting into place the turbine rotor
1516 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Suspended Load
danger
area.
Remove the rotor lifting device and store it at the appropriate place.
9.2.3 Check measurements after lifting into place the rotor

certificate
the inner casing, refer to the test certificate. HTGD
667 255
certificate
the outer casing, refer to the test certificate. HTGD
667 256
Check the backlash of the main lube oil pump according to the Test
certificate
667 265
certificate
tive to the inner casing, refer to the test certificate. HTGD
667 257
Check the radial and axial clearances of the stationary and the Test
certificate
rotating blading, refer to the test certificate. 1BSE
001 637
Check the radial and axial clearances of the balance piston, Test
certificate
refer to the test certificate. 1BSE
501 727
Check the radial and axial clearances of the HP shaft seal, re- Test
certificate
fer to the test certificate. 1BSE
501 726
Check the radial clearances of the LP shaft seal, refer to the Test
certificate
667 244
certificate
the LP blade carrier, refer to the test certificate. HTGD
667 260
en HTGD 693 000 V0140 A

1517
Note
The turbine rotor is in operating position.
9.3 Re-installing the journal bearing

12
MAD51
1518 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
Block
9.3.1 Installing the journal bearing upper part

Attach the journal bearing upper part 172 to the hoisting equipment and
lift it, refer to
Fig. 9-2.
Align the upper part with the cylindrical pins 174 and lower it carefully.

Fig. 9-2 Installing the journal bearing upper part
en HTGD 693 000 V0140 A

1519
WARNING
Suspended Load
danger
area.
Tighten the socket head screws 173, refer to document. Document

HTGD 630
147
Remove the shackle 815 and eyebolts 816 and also the hoisting
equipment.
9.3.2 Check measurements after installing the bearing

Check the radial and axial clearances of the journal bearing, Test
certificate
refer to the test certificate. HTGD 667
263
HTGD 667
459
1520 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
9.3.3 Installing the bearing bracket

Attach the bearing bracket 103 to the hoisting equipment, align it with the
bearing
and lower it carefully, refer to Fig. 9-3.
WARNING
Suspended Load
danger
area.
en HTGD 693 000 V0140 A

1521
816
115
815
817
107
103
109
BEAL0101_

107 Cylindrical bolt 816 Eyebolt
115 Cylindrical bolt 850 Bolt tensioning
device
Fig. 9-3 Installing the bearing bracket
Insert the cylindrical bolts 115 with the hoisting equipment and eyebolt 816
.
Tighten the bolted joint of the bearing bracket 107 and 109 with Document
the bolt tensioning device 850 , refer to Fig. 9-3 and docu- HTGD 630
147
ment.
1522 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Suspended Load
danger
area.
WARNING
Pressure hazard
danger
area.
Manufac-
ture) regulations.
Note
when tight-
ening the elongation bolts. Take note of the tool manufacturers
instructions.
9.4 Re-installing the LP shaft seal and enclosure

9.4.1 Installing the LP shaft seal
Attach the shaft seal upper part 402 with shackle 815 and ropes to the
hoisting
equipment and align it with the lower part 401, refer to Fig. 9-4.
Carefully lower the upper part with the hoisting equipment and align it
with taper pins
905 .
Tighten the socket head screws 405 in accordance with the
Document
pretension values given in document. Remove the taper pins HTGD
630 147
905 and store them in the tool cabinet.
en HTGD 693 000 V0140 A

1523
905
815
405
402
401
BGAC0202_

401 Shaft seal lower part 815 Shackle
402 Shaft seal upper part 905 Taper pin
Fig. 9-4 Installing the shaft seal upper part
Caution
Lower the shaft seal upper part vertically and keep the joint faces
horizontal to pre-
1524 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Suspended Load
area.
en HTGD 693 000 V0140 A

1525
9.4.2 Installing the instruments

Install the differential expansion transmitter 182 with holder re- Test
certificate
fer to Fig. 9-5. Adjust the differential expansion transmitter re- HTGD
479 364
fer to the test certificate.
Install the rotor vibration pick-ups 183 with holders. Adjust the Test
certificate
vibration pick-ups refer to the test certificate. HTGD
667 183
Fit the thermocouples 181 in the journal bearing lower part 171.
182 172 103
3 170 181 171
183 183
BFAS0202_
part
170 Oil shield lower part 182 Differential
expansion transmitter
171 Journal bearing lower part 183 Rotor vibration pick-
up
Fig. 9-5 Installing the instruments
1526 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
Note
Connect all electric connections for the thermocouples and instruments at
the bear-
ing casing in accordance with the markings applied during disassembly.
9.4.3 Installing the enclosure

Attach the enclosure 102 with the oil shield upper part 169, but without
cover 116, to
the hoisting equipment and align it horizontally using the chain hoist,
refer to Fig. 9-6.
Align the enclosure with the turbine axis and lower it carefully.
Tighten all socket head screws 121 on the enclosure outer side Document
in the parting plane in accordance with the pretension values HTGD 630 147
given in document.
en HTGD 693 000 V0140 A

1527

102 Bearing casing enclosure 402 Shaft seal upper part
121 Socket head screw 906 Jack screw (not
inserted)
169 Oil shield upper part 907 Taper pin
190 Hexagon head bolt 815 Shackle
191 Cover
Fig. 9-6 Installing the enclosure
Tighten the socket head screws 416 with washers 417 at the Document
shaft seal upper part 402 and the socket head screws 121 in HTGD 630
147
the parting plane in the enclosure interior through the openings
in the enclosure in accordance with the pretension values
given in document.
1528 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
Measure and record the radial clearance of the oil shield. Test
certificate
HTGD 499
343
HTGD 667
267
Note
Make sure that all screws in the enclosure interior are inserted.
Remove the taper pins 907 and store them in the tool cabinet.
Mount the cover 116 with hexagon head bolts 117 on both sides of the
enclosure.
Mount the cover 191 with hexagon head bolts 190.
9.5 Re-installing the HP shaft seal

Attach the shaft seal upper part 202 to the hoisting equipment and lower it
carefully,
refer to Fig. 9-7.
Align the upper part 202 with the lower part 201 in the parting plane using
taper pins
905 .
Caution
Lift the shaft seal upper part vertically and keep the joint faces horizontal
to prevent
damage to the sealing elements of the shaft seal.
en HTGD 693 000 V0140 A

1529

201 Shaft seal lower part 905 Taper pin
202 Shaft seal upper part 908 Jack screw (not
inserted)
203 Locking screw 815 Shackle
Fig. 9-7 Re-installing the shaft seal upper part
1530 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Suspended Load
danger
area.
Tighten the socket head screws 205 in accordance with the

Document
pretension values given in document. HTGD
630 147
9.6 Re-mounting the inner casing upper parts

9.6.1 Lifting into place the LP blade carrier upper part
Screw the guide bolts 917 on opposite sides into the blade carrier lower
part 151,
refer to Fig. 9-8.
Attach the blade carrier upper part 152 to the hoisting equip- Data
sheet
ment, to the data sheet "Disposition of slings". HTGD
667 271
1BSE
501 724
Note
Keep the casing horizontal when lifting it. Make sure that the guide bolts
move
en HTGD 693 000 V0140 A

1531
WARNING
Suspended Load
area.
1532 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
152
917
154, 850
155
153
916
915
152
A
A
918
916
917
151
917
BEAD0102_

151 Blade carrier lower part 850 Bolt tensioning
device
152 Blade carrier upper part 915 Jack screw (not
inserted)
155 Support ring 918 Shackle
Fig. 9-8 Re-installing the LP blade carrier upper part
Align the upper part 152 with the lower part 151 in the parting plane using
taper pins
916 , remove the guide bolts 917 and store them in the tool cabinet.
9.6.2 Tightening the parting flange bolts of the LP blade carrier

Tighten the flange joints 153 to 155 with the bolt tensioning de-
Test certificate
vice 850 , refer to Fig. 9-8 and the test certificate.
HTGD 667 238
en HTGD 693 000 V0140 A

1533
WARNING
Suspended Load
danger
area.
WARNING
Pressure hazard
danger
area.
Manufac-
ture) regulations.
Note
when tight-
instructions.
1534 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
9.6.3 Lifting into place the HP inner casing upper half

Screw the guide bolts 914 on opposite sides into the inner casing lower
half 51, re-
fer to Fig. 9-9.
Attach the inner casing upper half 52 to the hoisting equipment refer to
the data
sheet "Disposition of slings".
Note
Keep the casing horizontal when lifting it into place. Make sure that the
guide bolts
move freely in the bores.
en HTGD 693 000 V0140 A

1535
914 53,56
54,57 58,850
59,850
912
913
912
52
51
914
BEAD0101_

51 Inner casing lower half 58 Support ring
52 Inner casing upper half 59 Support ring
53 Elongation stud 850 Bolt tensioning
device
54 Elongation stud 912 Jack screw (not
inserted)
56 Nut 913 Taper pin
Fig. 9-9 Re-mounting the HP inner casing upper part
1536 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Suspended Load
danger
area.
Align the upper half 52 with the lower half 51 in the parting plane using
taper pins
913 , remove the guide bolts 914 and store them in the tool cabinet.
9.6.4 Tightening the parting flange bolts of the HP inner casing

Tighten the flange joints 53 to 59 with the bolt tensioning de- Test
certificate
vice 850 refer to Fig. 9-9 and the test certificate. HTGD 667
237
WARNING
Suspended Load
danger
area.
en HTGD 693 000 V0140 A

1537
WARNING
Pressure hazard
danger
area.
Manufac-
ture) regulations.
Note
when tight-
instructions.
9.7 Check measurements before re-mounting the outer casing

certificate
tive to the inner casing refer to the test certificate. HTGD
667 257
9.7.1 HP turbine
certificate
the inner casing refer to the test certificate. HTGD
667 255
9.7.2 LP turbine
certificate
the LP blade carrier refer to the test certificate. HTGD
667 260
9.8 Re-mounting the outer casing upper half

9.8.1 Lifting into place the outer casing upper half
Note
Check the cleanliness of the support surfaces of the cross-flange at the
outer cas-
ing upper part and the expansion joint before starting the assembly. The
surfaces
must be free of grease and dust. Clean them once again, if necessary. The
super-
seal at the cross-flange must be in proper condition.
Screw the guide bolts 908 on opposite sides into the outer casing lower
half 1 refer
to Fig. 9-10.
1538 HTGD 693 000 V0140 A
en
MAA10/MAC10 - HTGD693011V9020 -
Block
Attach the outer casing upper half 2 to the hoisting equipment Data
sheet
refer to Fig. 9-10 and the data sheet "Disposition of slings". HTGD 667
271
1BSE 501
724
Note
Keep the casing horizontal when lifting it into place. Make sure that the
guide bolts
move freely in the bores.
902
906
907
902
903 907 906
902
903
902
908
908
1
BEAB0102_

1 Outer casing lower half 903 Taper pin
2 Outer casing upper half 906 Jack screw (not
inserted)
3 Turbine rotor 907 Taper pin
902 Jack screw (not inserted) 908 Guide bolt
Fig. 9-10 Lifting on the outer casing upper half
en HTGD 693 000 V0140 A

1539
WARNING
Suspended Load
danger
area.
Align the upper half 2 with the lower half 1 in the parting plane using
taper pins 903
and 907 , remove the guide bolts 908 and store them in the tool cabinet.
9.8.2 Tightening the parting flange bolts of the outer casing

Tighten the flange joints 104, 105, 107 to 112 and 123 with the Test
certificate
bolt tensioning device 850 refer to the test certificate. HTGD 667
235
HTGD 667
236
Tighten the socket head screws 121 refer to Fig. 9-11 and the Document
pretension values given in document. HTGD 630
147
Tighten the flange joints 4, 7 and 11 to 13 with the bolt tension- Test
certificate
ing device 850 refer to the test certificate. HTGD 667
235
HTGD 667
236
WARNING
Suspended Load
danger
area.
1540 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Pressure hazard
area.
Make sure to correctly follow the local and OEM (Original Equipment Manufac-
ture) regulations.
Note
when tight-
ening the elongation bolts. Take note of the tool manufacturers instructions.
en HTGD 693 000 V0140 A

1541
121
4,7,11,12
13,850
202
107,108,109, 1 105,108,109,
110,123,850 110,123,850
203
104,108,109,
110,123,850
109,110,111,
204 112,123,850
201
BEAB0101_

1 Outer casing lower half 109 Nut
2 Outer casing upper half 110 Cover
4 Elongation stud 111 Elongation bolt
7 Nut 112 Expansion
sleeve
11 Support ring 121 Socket head
screw
12 Cover 123 Hexagon head
bolt
13 Hexagon head bolt 201 Shaft seal
lower part
104 Elongation stud 202 Shaft seal
upper part
105 Elongation stud 203 Hexagon head
bolt
107 Elongation stud 204 Locking wire
108 Support ring 850 Bolt tensioning
device
Fig. 9-11 Tightening the parting flange bolts

1542 HTGD 693 000 V0140 A
en
MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
Remove the taper pins 903 and 907 and store them in the tool
cabinet.
9.8.3 Securing the HP shaft seal

Screw the hexagon head bolts 203 into the shaft seal upper part 202 refer
to Fig. 9-
11 and secure the upper part.
Secure the hexagon head bolts 203 at the upper part 202 and lower part 203
with
locking wire 204.
9.8.4 Loosening the HP casing support

Loosen slowly the jack screws 901 , which have supported temporarily the
outer
casing during overhaul, on both sides of the outer casing lower half 1
refer to Fig. 9-
12 and remove them.
Note
Place dial gauges on both sides and supervise the lowering. The vertical
position of
the outer casing must not be changed.
Store the jack screws 901 in the tool cabinet.
en HTGD 693 000 V0140 A

1543

1 Outer casing lower half 901 Jack screw
2 Outer casing upper half 904 Dial gauge with gauge rack
100 Bearing pedestal lower part
Fig. 9-12 Loosening the casing support
1544 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
9.9 Check measurements after re-mounting the outer casing

9.9.1 HP turbine
Check the radial and the axial position of the rotor in the outer Test
certificate
casing refer to the test certificate. HTGD
667 256
Check the guide clearances and fixing elements refer to the Test
certificate
667 247
Screw the screw plugs 13 with seal rings 14 into the outer casing bottom
refer to Fig.
9-13.
13,14
BGAG0103_
13 Screw plug 14 Seal ring
Fig. 9-13 Closing off the measurement plane
9.9.2 LP turbine
Check the relative rotor position in the LP blade carrier refer to Test
certificate
the test certificate. HTGD
667 260
Access through the rupture diaphragm opening and manhole at the condenser
neck.
en HTGD 693 000 V0140 A

1545
9.10 Additional work

9.10.1 Installing the water injection pipe
Install the elbow 143 with seals 144 refer to Fig. 9-14.
Tighten the bolted joint 145 to 147 refer to the pretension val-
Document
ues given in document. HTGD
630 147

2 Outer casing upper half 145 Hexagon head bolt
143 Elbow 146 Washer
144 Seal 147 Hexagon nut
Fig. 9-14 Installing the pipe
1546 HTGD 693 000 V0140 A

en
MAA10/MAC10 - HTGD693011V9020 -
Block
9.10.2 Installing the expansion joint bolting
Note
Check the cleanliness of the support surfaces of the cross-flange at the
outer cas-
ing upper part and the expansion joint before starting the assembly. The
surfaces
must be free of grease and dust. Clean them once again, if necessary. The
super-
seal at the cross-flange must be in proper condition.
Fasten the five upper cover flanges 135 with support plates 139 refer to
Fig. 9-15
with hexagon head screws 138.
Note
Make sure that the expansion joint rests uniformly and without warping
against the
flange.
Tighten the hexagon head screws 138 refer to the pretension Document
values given in document. HTGD 630
147
Mount the cover 137 (5-part) with hexagon head bolts 136 and washers 140.
en HTGD 693 000 V0140 A

1547
BGAX0201A

2 Outer casing upper half 137 Cover (5-part)
130 Condenser neck 138 Hexagon head screw
132 Expansion joint 139 Support plate
133 Super seal 140 Washer
134 Hexagon head screw 141 Hexagon nut
135 Cover flange (8-part) 142 Washer
136 Hexagon head bolt 150 Lockwasher
Fig. 9-15 Installing the expansion joint bolting
The condenser is again connected with the LP turbine.
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9.10.3 Installing the rupture diaphragm and refitting the manhole covers
Place the seal 127 on the support surface at the outer casing upper half
refer to Fig.
9-16 and mount the rupture diaphragm 129 with the rupture diaphragm
support 126
on the upper half.
BGAX0301_
A2468

126 Rupture diaphragm support 129 Rupture diaphragm
assembly
127 Seal 130 Condenser neck
128 Hexagon head bolt 131 Manhole
Fig. 9-16 Mounting the rupture diaphragm
Tighten the hexagon head bolts 128 refer to the pretension

Document
values given in document. HTGD
630 147
Close the manhole 131 at the condenser neck.

If the two rupture diaphragms at the condenser neck were also removed,
they have
to be installed again as described above.
en HTGD 693 000 V0140 A

1549
9.11 Final remarks

Note
Tighten and secure all screws and bolts without recorded Document
prestress according to document. HTGD 630 147
Note
Re-connect all thermocouples and instruments of the turbine refer to the
markings
applied during disassembly and check their functioning.
Clean all tools used for maintenance, check their completeness and store
them in
the tool cabinets.
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MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 10
RE-ASSEMBLY OF THE VALVES
en HTGD 693 000 V0140 A 1551

10 RE-ASSEMBLY OF THE VALVES

Fig. 10-1 shows the assembly situation of the live steam valve.

Fig. 10-1 Live steam valve assembly
10.1 Re-installing the control valve diffuser

Starting point
The high pressure turbine is re-assembled and ready for re-installing the
valves.
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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
10.1.1 Installing the diffuser

Fasten the tools and the support tube 812 to the diffuser 422
according to Fig. 10-
2. Remove the six point socket 845 .
Attach the unit consisting of tools and diffuser to the hoisting Data
sheet
equipment according to the data sheet using ropes. HTGD
667 233
Make sure that the unit hangs horizontally at the hoisting equipment and
insert the
diffuser in the valve housing until it engages.

422 Diffuser 816 Hexagon head bolt
812 Support tube 840 Holder
813 Socket head screw 841 Socket head screw
814 Weight 845 Six point socket
Fig. 10-2 Installing the diffuser
en HTGD 693 000 V0140 A

1553
WARNING
Suspended Load
danger
area.
Remove the tools.
10.1.2 Screwing together the diffuser

Screw together the diffuser 422 according to Fig. 10-3.

422 Diffuser
Fig. 10-3 Screwing together the diffuser
Tighten alternately the elongation bolts 421 according to Document

document. HTGD 630
147
Remove the six point socket 845 .
1554 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block

Starting point
The control valve internals are re-assembled and ready for re-
installation.
12
MAA12AA011
10.2.1 Arranging the assembly tools

Turn the adapter piece 838 onto the thread of the lock 419 according to
Fig. 10-4.
Push the spacer tube 837 over the valve spindle 418 and fasten it with a
coupling
nut 402 to lock the valve spindle.
Attach the support tube 812 using socket head screws 839 to the
adapter piece
838 mounted on the lock 419.
Mount the weight 814 with the hoisting equipment on the Data
sheet
support tube 812 according to the data sheet and secure it HTGD
667 233
with a hexagon head bolt 816 .
Note
Attach the unit consisting of valve internals and tools with Data
sheet
ropes horizontally to the hoisting equipment according to the HTGD
667 233
data sheet.
en HTGD 693 000 V0140 A

1555
Install the support 832 .

418 Valve spindle 832 Support
419 Lock 837 Spacer tube
814 Weight 839 Socket head screw
Fig. 10-4 Arranging the tools
WARNING
Suspended Load
danger
area.
10.2.2 Inserting and moving into place the valve internals

Insert the valve internals according to Fig. 10-4 in the control valve 400
and remove
the tools.
Fit the seal ring 420 and the clamping ring 417 according to Fig. 10-5.
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Mount the tools according to Fig. 10-5 and push the clamping ring 417, seal
ring 420
and lock 419 with hexagon head bolts 835 so far into the valve housing 400
that
the groove in which the support 832 rests becomes visible along the complete
cir-
cumference and freely accessible.

400 Control valve 803 Clamping piece
415 Hexagon nut 832 Support
416 Elongation stud 833 Washer
417 Clamping ring 834 Jack plate
419 Lock 835 Hexagon head bolt
420 Seal ring
Fig. 10-5 Moving into place the control valve internals
Remove the tools.
en HTGD 693 000 V0140 A

1557
10.2.3 Installing the segment ring

Install the segment ring 414 according to Fig. 10-6 and secure it at the
top against
dropping with a hexagon head bolt 801 and a washer 802 .

414 Segment ring 802 Washer
Fig. 10-6 Installing the segment ring
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10.2.4 Installing the intermediate piece

Attach the intermediate piece 401 according to Fig. 10-7 to the hoisting
equipment,
align it horizontally with the chain hoist and move it towards the valve
housing.
823
415,416
414
410,411
401 412
B
822 413
A
851
850
414
801
802 BVAC0202_

401 Intermediate piece 416 Elongation
stud
410 Hexagon nut 801 Hexagon head
bolt
412 Locking ring 822 Jack screw
(not inserted)
413 Screw plug 850 Socket
spanner
414 Segment ring 851 Socket
spanner
415 Hexagon nut
Fig. 10-7 Installing the intermediate piece
en HTGD 693 000 V0140 A

1559
WARNING
Suspended Load
danger
area.
Tighten the hexagon nuts 415 according to document.

Document
HTGD
630 147
Remove the hoisting equipment from the intermediate piece.

Screw on the locking ring 412. Use hexagon socket spanners
Document
850 , 851 to tighten hexagon head bolts 411 refer to docu- HTGD
630 147
ment and secure them with nuts 410.
Remove the hexagon head bolt 801 and washer 802 and close the
opening with
a screw plug 413.
10.2.5 Mounting the coupling parts and heat shield

Put the distance sleeve 407 onto the valve spindle 418, refer to Fig. 10-
8.
Mount the shield plates 406 with hexagon head bolts 404 and secure them
with lock-
ing plates 405. Attach the distance sleeve 407 with bolts 408.
Push the coupling sleeve 301 with hexagon head bolts 302 onto the valve
spindle
418.
Screw the coupling nut 402 onto the valve spindle 418 according to the
markings
applied during disassembly and lock it with a rollpin 403.
Note
position of the
1560 HTGD 693 000 V0140 A

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HTGD693011V9020 -
Turbine Block
403
402
418
BVAC0201_

301 Coupling sleeve 406 Shield plate, two-
part
302 Hexagon head bolt 407 Distance sleeve
402 Coupling nut 408 Hexagon head bold
403 Rollpin 409 Locking plate
404 Hexagon head bolt 418 Valve spindle
405 Locking plate
Fig. 10-8 Mounting the coupling and heat shield
Measure the valve stroke and fitting dimensions and compare Test
certificate
them with the specified data. HTGD
667 206
10.3 Re-installing the control valve actuator

Starting point
The control valve actuator is re-assembled and ready for re-installation.
12
MAA12AA011
en HTGD 693 000 V0140 A

1561
10.3.1 Attaching the control valve actuator to the valve

Attach the control valve actuator 300 according to Fig. 10-9 to the
hoisting equip-
ment using ropes and a chain hoist.
Take up the actuator weight with the hoisting equipment and align it
horizontally with
the chain hoist.
Move the control valve actuator towards the intermediate piece 401 and
align it.
WARNING
Suspended Load
danger
area.
Screw the control valve actuator 300 with socket head screws 304 and
spring wash-
ers 305 uniformly to the intermediate piece 401 according to Fig. 10-9.
Note
Turn the socket head screws 304 alternately to pull the actuator into
position.
Measure Y is approx. 120 mm.
Remove the control valve actuator from the hoisting equipment.

Tighten the socket head screws 304 according to document. Document
HTGD 630
147
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HTGD693011V9020 -
Turbine Block
730 306 401
300
304,305 304,305
Y
306 306
401 401
BTAB0402_

Fig. 10-9 Mounting the control valve actuator
10.3.2 Connecting the actuator and the valve

Screw the coupling sleeve 301 with hexagon head bolts 302 to the actuator
piston
306 according to Fig. 10-10.
Note
Tightening torque: 50 Nm.
The control valve actuator is again connected with the control valve.
en HTGD 693 000 V0140 A

1563
306 401
300
302
301
401
BTAB0401_

301 Coupling sleeve 401 Intermediate piece
Fig. 10-10 Connecting the control valve actuator and the valve
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10.4 Re-installing the stop valve diffuser

10.4.1 Installing the diffuser
Fasten the tools and the support tube 812 to the diffuser 222 according to
Fig. 10-
11. Remove the six point socket 820 and the cover 824 .
Attach the unit consisting of tools and diffuser horizontally to Data
sheet
the hoisting equipment according to the data sheet using HTGD
667 232
ropes.
Make sure that the unit hangs horizontally at the hoisting equipment and
insert the
diffuser in the valve housing until it engages.

200 Stop valve 816 Hexagon head bolt
222 Diffuser 818 Holder
812 Support tube 819 Socket head screw
813 Socket head screw 820 Six point socket
814 Weight 824 Cover
815 Eyebolt
Fig. 10-11 Installing the diffuser
en HTGD 693 000 V0140 A

1565
WARNING
Suspended Load
danger
area.
Remove the tools.
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10.4.2 Screwing together the diffuser

Screw together the diffuser 222 according to Fig. 10-12.

222 Diffuser
Fig. 10-12 Screwing together the diffuser
Tighten alternately the elongation bolts 221 according to

Document
document. HTGD
630 147
Remove the six point socket 817 .

Starting point
The stop valve internals are re-assembled and ready for re-installation.
12
MAA12AA001
en HTGD 693 000 V0140 A

1567
10.5.1 Arranging the assembly tools

Push the spacer tube 810 over the valve spindle 218 according to Fig. 10-
13 and
fasten it with a coupling nut 202 to lock the valve spindle.
Screw the adapter piece 811 onto the lock 219 and fasten the support tube
812
with socket head screws 813 .
Mount the weight 814 with the hoisting equipment on the Data
sheet
support tube 812 according to the data sheet and secure it HTGD 667
232
with a hexagon head bolt 816 .
Note
Attach the unit consisting of valve internals and tools with Data
sheet
ropes horizontally to the hoisting equipment according to the HTGD 667
232
data sheet.
Install the support 807 .

200 Stop valve 811 Adapter piece
202 Coupling nut 812 Support tube
218 Valve spindle 813 Socket head screw
219 Lock 814 Weight
807 Washer 815 Eyebolt
810 Spacer tube 816 Hexagon head bolt
Fig. 10-13 Arranging the tools
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WARNING
Suspended Load
danger
area.
10.5.2 Inserting and moving into place the valve internals

Insert the valve internals according to Fig. 10-13 in the stop valve 200
and remove
the tools.
Fit the seal ring 220 and clamping ring 217 according to Fig. 10-14.
Mount the tools according to Fig. 10-14 and push the clamping ring 217,
seal ring
220 and lock 219 with hexagon head bolts 805 so far into the valve housing
200
that the groove in which the support 807 rests becomes visible along the
complete
circumference and freely accessible.
en HTGD 693 000 V0140 A

1569

200 Stop valve 220 Seal ring
215 Hexagon nut 803 Clamping piece
216 Elongation stud 804 Jack plate
217 Clamping ring 805 Jack screw
219 Lock 807 Support
Fig. 10-14 Moving into place the stop valve internals
Remove the tools.
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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
10.5.3 Installing the segment ring

Install the segment ring 214 according to Fig. 10-15 and secure it at the
top against
dropping with a hexagon head bolt 801 and washer 802 .

214 Segment ring 802 Washer
Fig. 10-15 Installing the segment ring
en HTGD 693 000 V0140 A

1571
10.5.4 Installing the intermediate piece

Attach the intermediate piece 201 according to Fig. 10-16 to the hoisting
equipment,
align it horizontally with a chain hoist and move it towards the valve
housing.
823
A
216 213
214
215
201 211 210 212
822
801
802
A
214
BVAB0202_

201 Intermediate piece 215 Hexagon nut
210 Hexagon nut 216 Elongation
stud
211 Hexagon head bolt 801 Hexagon head
bolt
212 Locking ring 802 Washer
213 Screw plug 822 Jack screw
214 Segment ring 823 Shackle
Fig. 10-16 Installing the intermediate piece
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WARNING
Suspended Load
danger
area.
Tighten the hexagon nuts 215 according to document. Document

HTGD 630
147
Remove the hoisting equipment from the intermediate piece.

Screw on the locking ring 212.
Tighten the hexagon head bolts 211 according to document Document
and secure them with nuts 210. HTGD 630
147
Remove the hexagon head bolt 801 and washer 802 and close the
opening with
a screw plug 213.
10.5.5 Mounting the coupling parts and heat shield

Push the coupling cover 101 with hexagon head bolts 102 and locking plates
103
onto the valve spindle 218 according to Fig. 10-17.
Screw the coupling nut 202 onto the valve spindle 218 according to the
markings
applied during disassembly and secure it with a rollpin 203.
Note
position of the
en HTGD 693 000 V0140 A

1573
206
203 103 102 201
202 101
218
204,205
BVAB0201_

101 Coupling cover 203 Rollpin
103 Locking plate 205 Locking plate
201 Intermediate piece 206 Shield plate, two-part
202 Coupling nut 218 Valve spindle
Fig. 10-17 Mounting the coupling and the heat shield
Measure the valve stroke and fitting dimensions and compare Test
certificate
then with the specified data. HTGD 667
205
Install the shield plates 206 with hexagon head bolts 204, and secure them
with lock-
ing plates 205.
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10.6 Re-installing the stop valve actuator

Starting point
The stop valve actuator is again assembled and ready for re-installation.
12
MAA12AA001
10.6.1 Attaching the stop valve actuator to the valve

Attach the stop valve actuator 100 to the hoisting equipment according to
Fig. 10-18
using ropes and a chain hoist.
Take up the actuator weight with the hoisting equipment and align it
horizontally with
the chain hoist.
Move the stop valve actuator towards the intermediate piece 201 and align
it.
WARNING
Suspended Load
danger
area.
Screw the stop valve actuator 100 with socket head screws 104 and spring
washers
105 uniformly to the intermediate piece 201 according to Fig. 10-18.
Note
Turn the socket head screws 104 alternately to pull the actuator into
position.
Measure X is approx. 120 mm.
Remove the hoisting equipment from the stop valve actuator.

Tighten the socket head screws 104 according to document.
Document
HTGD
630 147
en HTGD 693 000 V0140 A

1575
703 201
100
104, 105 201 104, 105 201
106 106
BTAA0302_

100 Stop valve actuator 106 Actuator piston
104 Socket head screw 201 Intermediate
piece
Fig. 10-18 Mounting the stop valve actuator
10.6.2 Connecting the actuator and the valve

Screw the coupling cover 101 with hexagon head bolts 102 to the actuator
piston
106 according to Fig. 10-19.
Note
Tightening torque: 56 Nm.
Secure the hexagon head bolts with locking plates 103.
1576 HTGD 693 000 V0140 A

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The stop valve actuator is again connected with the stop valve.

100 Stop valve actuator 103 Locking plate
101 Coupling cover 106 Actuator piston
102 Hexagon head bolt 201 Intermediate piece
Fig. 10-19 Connecting the stop valve actuator and the valve
en HTGD 693 000 V0140 A 1577

10.7 Moving the swing arm support into the operating position
12
MAA12BQ001
Bring the swing arm support with hexagon head bolts 510 and Data
sheet
hexagon nuts 511 again into the operating position according HTGD 667
231
to Fig. 10-20.
BNAA0102_

506 Belleville spring assembly 511 Hexagon nut
510 Hexagon head bolt 600 Valve housing
Fig. 10-20 Operating position of the swing arm support
10.8 Final work

Note
Tighten and secure all screws and bolts without recorded Document
prestress according to document. HTGD 630
147
1578 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
Note
them in
the tool cabinets.
10.8.1 Electrical connections

Re-connect all electrical connections of the control and stop valve
actuators accord-
ing to the markings applied during disassembly and check their
functioning.
10.8.2 Hydraulic pressure supply

Re-connect all hydraulic supplies of the control and stop valve actuators.
Caution
Make sure to keep very high standards of cleanliness during re-assembly.
Close again the system drain valves.
Note
According to the test certificate check the pre-charging pressure of the
bladder ac-
cumulator of the hydraulic pressure generation system. Re-charge, if
necessary.
Start the pumps for hydraulic pressure generation and check the tightness
of the
safety system.
10.9 Stroke test of the valves

10.9.1 Stop valve with actuator
Test the stroke of the stop valve coupled with the stop valve Test
certificate
actuator according to the test certificate. HTGD 667
205
10.9.2 Control valve with actuator

Test the stroke of the control valve coupled with the control Test
certificate
valve actuator according to the test certificate. HTGD 667
206
en HTGD 693 000 V0140 A

1579
Blank Page
1580 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 11
RE-ASSEMBLY OF THE EXPANSION SLEEVE COUPLING
en HTGD 693 000 V0140 A 1581

11 RE-ASSEMBLY OF THE COUPLING

The coupling, designed as an expansion sleeve coupling, is arranged
between the
Turbine and the Generator.
12
MAK21
Preliminary remark
To prevent bending stresses, screw together the two coupling flanges, so
that they
are exactly parallel, observing the prescribed tolerances.
11.1 Preparations
The journal areas must be adjusted in accordance with the calculated
deflection line
before installing the turbine rotors.
Measure the elevation of the journal areas and record the val- Test
certificate
ues in the alignment diagram. 1BSE
501 730
The positions of the journal areas must be checked even if they were not
changed
during maintenance.
The rotors must be straight and not deformed due to heat.
Note
The rotors may only rest on the journal areas and not on the auxiliary
bearings or
similar units when checking the alignment condition.
All heavy machine parts must be at their correct location so that the
deflection line of
the foundation table corresponds to the line expected in operation.
The rotor zero markings (bores, 4 mm) must align in the longitudinal
axis of the
turbine line.
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11.2 Pulling together the coupling flanges

Pull together the two coupling flanges with the two coupling bolts 3 to a
gap "a" = 1
mm according to Fig. 11-1 using the hydraulic tensioning device 23 and
minimum
oil pressure at connection C.

10 Face spanner
Fig. 11-1 Pulling together the coupling flanges
The jacking oil system must be in operation when pulling together the
coupling
flanges.
Insert two jack screws 22 diametrically opposite and staggered by 90�
relative to
the coupling bolts into the bores for the balancing plugs according to Fig.
11-2.
en HTGD 693 000 V0140 A

1583

22 Jack screw
Fig. 11-2 Inserting the jack screws
Tighten slightly the jack screws to prevent the rotor from moving axially
when rotat-
ing it for taking the measuring series.
Adjust dimension "a" according to the test certificate. Test
certificate
HTGD
667 270
11.3 Aligning the coupling

11.3.1 Checking the parallelism
Checking the parallelism means measuring the angular misalignment and
axial run-
out of the coupling flanges relative to one another.
Both faults manifest themselves in the same way (different gap width "a"
on the cir-
cumference of the coupling) and can only be measured as the sum of both.
The system described in the test certificates allows, however, correction
of the angu-
lar misalignment.
The angular misalignment (incorrect alignment) is caused by faulty
erection and can
be completely eliminated by correcting the horizontal and vertical
positions of the
journal areas.
The axial run-out (the coupling faces are not exactly perpendicular to the
rotor axes
due to admissible tolerances) is a manufacturing defect and cannot be
corrected.
The tolerance for the axial run-out of each coupling face may not exceed
0.015 mm.
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11.3.2 Measuring the angular misalignment

The angular misalignment is determined by four measuring series. A
measuring se-
ries consists of measuring the gap width "a" at four exactly defined
points on the
coupling circumference.
Take the measuring series according to the test certificate for Test
certificate
"left", "right", "top" and "bottom". HTGD
667 270
Note
The jacking oil system must be switched off when taking the measurements
be-
cause its pulsations could affect the measurement results.
Proceed as follows for taking a measuring series:

a) Switch off the jacking oil system.
b) Loosen the jack screws by about 1/4 turn.
c) Loosen the coupling bolts by about 1/4 turn.
d) Measure the distances "a" at the points "left", "right", "top" and
"bottom" and enter
the values in the test certificate.
In most cases it is not possible to measure at point "bottom"; this,
however, does not
affect the result.
e) Tighten slightly the coupling bolts and jack screws. Maintain the
distance "a" =
max. 1 mm.
f) Start the jacking oil system and rotate the rotor through 90� each
time.
Evaluate the data obtained by the four measuring series. Carry out the
necessary
corrections in two steps.
11.3.3 Correcting the angular misalignment

a) First step - Correct angle = horizontal component of the angular
misalignment
by lateral shifting of the journal area(s) until the mean values of the
measuring
points "left" and "right" are identical or at least within the
tolerances given in the
test certificate. Try to reach the ideal case "left" = "right".
b) Second step - Correct angle = vertical component of the angular
misalignment
by lifting or lowering the journal area(s) until the mean values of the
measuring
points "left", "right", "top" and "bottom" are identical or at least
within the toler-
ances given in the test certificate. Try to reach the ideal case "left"
= "right" =
"top" = "bottom".
Remove the jack screws and coupling parts.
en HTGD 693 000 V0140 A

1585
11.4 Centring the coupling

11.4.1 Preparations
Check whether the coupling flanges align radially and whether the rotor
zero mark-
ings, bores with a dia. of 4 mm, are in alignment in longitudinal
direction along the ro-
tor axis.
Clean the coupling bores and switch on the jacking oil system.
Note
Lubricate all coupling parts to be installed provisionally and all
coupling bores with
MoS2 powder 1 or Neolube No. 2 to permit easier dismantling.
11.4.2 Centring the coupling bores

Align the coupling bores with the aid of two centring sleeves 19 ,
installed diametri-
cally opposite, and coupling bolts 3 according to Fig. 11-3.

3 Coupling bolt 19 Centring sleeve
Fig. 11-3 Centring the coupling bores
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11.4.3 Pulling together the coupling

Insert provisionally four coupling bolts 3 with countersunk nuts 4,
staggered by about
90�, and tighten them completely according to Fig. 11-4 using the
tensioning device
23 and minimum oil pressure at connection C of the hydraulic cylinder.

10 Face spanner
en HTGD 693 000 V0140 A

1587
11.4.4 Tensioning radially the centring sleeves

Tension radially the already installed centring sleeves 19 and Test
certificate
coupling bolts 3 according to Fig. 11-5 using the tensioning de- HTGD 667
270
vice 23 and an oil pressure of p1 + 10 MPa according to the
test certificate at connection C of the hydraulic cylinder.

8 Spacer ring 19 Centring sleeve
Fig. 11-5 Tensioning radially the centring sleeves
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11.4.5 Tensioning provisionally the coupling bolts

Tension provisionally the four inserted coupling bolts 3, without Test
certificate
expansion sleeves, according to Fig. 11-6 using the tensioning HTGD
667 270
device 23 and an oil pressure of p2 according to the test cer-
tificate at connection C of the hydraulic cylinder.

10 Face spanner
11.5 Tensioning definitely the coupling bolts

Note
Clean thoroughly all coupling parts and coupling bores before the definite
assem-
bly.The surfaces of the expansion sleeves are browned or phosphated; this
coating
may not be damaged or removed.
Lubricate the coupling parts to be installed and the coupling bores
completely and
adequately with MoS2 powder 1 or Neolube No. 2.
en HTGD 693 000 V0140 A

1589
11.5.1 Inserting the coupling bolts

Insert the coupling bolts 3 with mounted expansion sleeves 6 in center
position in the
coupling bore according to Fig. 11-7. The large opening of the internally
conical ex-
pansion sleeve is on side B, which has less space. Use the tension bolt 7
for posi-
tioning.

3 Coupling bolt 7 Tension bolt
6 Expansion sleeve
Fig. 11-7 Inserting the coupling bolts
11.5.2 Mounting the tensioning device

Mount the spacer ring 8 and the support ring 11 on the coupling
bolt and the
tension bolt according to Fig. 11-8.
Note
Position the bevelled area of the support ring parallel to the shaft
contour to pre-
vent grooves in the coupling flange. The support ring must always rest
against the
coupling flange.
Bolt the tensioning device 23 to the tension bolt according to Fig. 11-8
until the
spacer ring 8 is pressed against the expansion sleeve 6.
Before tensioning the expansion sleeves check with a 0.02 mm feeler gauge
at four
points of the coupling flange circumference, staggered by 90� each time,
whether the
coupling flanges have been completely pulled together.
1590 HTGD 693 000 V0140 A

en
MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block

6 Expansion sleeve 11 Support ring
8 Spacer ring 23 Tensioning device
Fig. 11-8 Mounting the tensioning device
It must still be possible to rotate all installed parts, including the

tools, as a single unit
in the coupling bore.
11.5.3 Pre-tensioning the coupling bolts

Build up the pressure p1 according to the test certificate at connection C
of the hy-
draulic cylinder.
Note
Check whether the support ring still rests against the coupling flange.
The material of the expansion sleeve is such that the pulling force of the
tensioning
device expands the expansion sleeve which eliminates the clearance between
the
expansion sleeve and the coupling bore and provides radial pre-tension.
If the unit consisting of coupling bolt and expansion sleeve can still be
rotated with
the tensioning device, increase the pressure p1 in steps of 50 bar until a
clearance-
free fit is ensured.
Record the actually built-up pressure p1 in the test certificate.
Test certificate
HTGD 667 270
Decrease the oil pressure p1 and remove the tools .
en HTGD 693 000 V0140 A

1591
11.5.4 Measuring the fitting clearance

Measure the fitting clearance "S", min.: 2 mm, to ensure that the
countersunk nuts to
be installed rest on the support surfaces of the coupling flange and not
on the ex-
pansion sleeve.
Measure the dimension "S" with a depth gauge or similar Test
certificate
measuring instrument and record the value in the test certifi- HTGD
667 270
cate.
11.5.5 Screwing on and marking the countersunk nuts

Screw on the countersunk nuts 4 with locking rings 5 according to Fig. 11-
9 and
tighten them manually. Apply markings on the facesides of the countersunk
nuts and
on the coupling flange to check the angle of rotation after tightening.
11.5.6 Tensioning the coupling bolts

Install the carrier ring 9 , support ring 11 and tensioning device 23
according to
Fig. 11-9.

9 Carrier ring
Fig. 11-9 Pre-tensioning the coupling bolts
Build up the oil pressure according to the test certificate via an

intermediate pressure
p2 at connection C and tighten the nuts on coupling side A using the
mandrel 18
and the carrier ring 9 . The sequence of tightening the coupling bolts is
optional.
1592 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block

certificate
HTGD
667 270
Decrease the oil pressure and remove the tools .
11.5.7 Removing the provisionally inserted coupling bolts

Remove again the four coupling bolts, which were inserted without
expansion
sleeves, according to Fig. 11-10.

10 Face spanner
Fig. 11-10 Removing the provisionally inserted coupling bolts
en HTGD 693 000 V0140 A

1593
11.5.8 Removing the centring sleeves

Remove again the two coupling bolts, inserted with slotted centring
sleeves, accord-
ing to Fig. 11-11.

3 Coupling bolt 12 Hydraulic cylinder
7 Tension bolt 19 Centring sleeve
8 Spacer ring 20 Intermediate ring
11 Support ring
Fig. 11-11 Removing the centring sleeves
11.5.9 Pre-tensioning the remaining coupling bolts

Pre-tension the remaining six coupling bolts according to 11.5.1 through
11.5.6 in the
same way and record the oil pressure p2.
certificate
HTGD
667 270
1594 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
11.5.10 Tensioning definitely the coupling bolts

Tension all coupling bolts with the definite oil pressure p3 according to
the test certifi-
cate in optional sequence according to Fig. 11-12.
Maintain a clearrance of 1 - 2 mm between the hydraulic cylinder and the
support
ring 11 when screwing on the cylinder to facilitate subsequent
dismantling of the
hydraulic cylinder 12 .

9 Carrier ring
Fig. 11-12 Tensioning definitely the coupling bolts
11.5.11 Checking the coupling assembly

Compare the angles of rotation of the countersunk nuts 4 with the aid of
the mark-
ings to check the coupling assembly. Check the oil pressure p3 in case of
deviations
and re-tension, if necessary.
Record the definite oil pressure p3 in the test certificate.
Test certificate
HTGD 667 270
11.5.12 Securing the countersunk nuts

Secure the countersunk nuts according to Fig. 11-13 on sides A and B of
the cou-
pling flanges by bending up and in the locking rings 5.
en HTGD 693 000 V0140 A

1595
Side A shows the unsecured, side B the secured condition.
Note
The coupling bolts shall not project beyond the countersunk nuts.

4 Countersunk nut 24 Screw plug
5 Locking ring
Fig. 11-13 Bending the locking rings
11.6 Checking the concentric run

The assembly of the coupling is extremely important for the smooth running
of the
turboset.
It is therefore necessary to check the concentric run of all assembled
couplings.
Check the concentric run of the coupling, assembled thor- Test
certificate
oughly and in accordance with instructions, according to the HTGD 667
270
test certificate.
Note
Inadmissible radial run-out defects of a coupling can be caused by damages.
1596 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
11.7 Final work

Coat the complete coupling with an anticorrosive like Tectyl 506 or Tectyl
175-GW
after checking the concentric run.
Clean thoroughly all tools used, check their completeness and store them
in the
tool cabinets.
en HTGD 693 000 V0140 A

1597
Blank Page
1598 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 12
RE-ASSEMBLY OF THE THRUST BEARING PEDESTAL
en HTGD 693 000 V0140 A 1599

12 RE-ASSEMBLY OF THE THRUST BEARING PEDESTAL

The journal thrust bearing pedestal is located between the HP / LP
turbine and the
generator.
12
MAD20
12.1 Starting point

The turbine and generator rotor is already installed and rests on the
shaft raising de-
vice, refer to Fig. 12-1.
12.2 Installing the bearings

12.2.1 Installing the combined thrust and journal bearing lower part
12
Refer to parts lists and component description:
MAD21
Insert carefully the combined thrust and journal bearing lower part 1and
2 in the
bearing pedestal using the hoisting equipment and secure it, according to
Fig. 12-1
and the component description of the bearing.
Note
Lubricate the bearing surfaces of the turbine rotor with a small quantity
of lube oil.
Make sure that the axial and radial position of the bearing in the
bearing pedestal
relative to the turbine rotor has not been changed compared with the
setting data
recorded before disassembly.
1600 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
12.2.2 Removing the shaft raising device

Relieve the rotor raising device 3 and remove completely, refer to
Fig. 12-1.
Note
Check the bearings load.
1, 2
BLNW0302_
A2461

1 Bearing body lower part 3 Rotor raising device
2 Journal bearing shell lower part
Fig. 12-1 Removing the shaft raising devices
en HTGD 693 000 V0140 A

1601
12.2.3 Lifting in the journal bearing, upper part

Arrange the tools and carefully set the upper part 2 of the bearing down
on the bear-
ing area, refer to Fig. 12-2.
Note
Lubricate the running surfaces of the bearing shells and pads with a smal
quantity
of lube oil. Make sure to keep all components absolutely clean.
Locate the upper part with cylindrical pins 4 and install the locking pin
5, refer to Fig.
12-2.
Tighten the socket head screws 3 according to the pre-stress
Document
values of document. HTGD
630 147
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MAA10/MAC10 - HTGD693011V9020 -
Block
5
2
BLNL0303_
A2460

1 Journal bearing, lower part 5 Locking pin
2 Journal bearing, upper part 6 Eyebolt
4 Cylindrical pin
Fig. 12-2 Lifting in the journal bearing upper part
en HTGD 693 000 V0140 A

1603
WARNING
Suspended Load
danger
area.
Measure the lift of the journal area according to the values in Test
certificate
the alignment of the test certificate. Re-adjust the final position 1BSE
501 730
if required.
12.3 Mounting the thrust bearing, upper part

12.3.1 Installing the sets of pads
Put the spring ring lower parts 7 and 9 in horizontal position and set the
lower sets of
pads 8 and 10 on the spring rings, refer to Fig. 12-3.
Put the spring ring lower parts 7 and 9 with mounted pads manually to the
rotor col-
lar and turn it into the thrust bearing lower part.
Mount the locking plates 11 with countersunk screws 12 on both sides.
Put the spring ring upper parts 7 and 9 in horizontal position and set the
upper sets
of pads 8 and 10 on the spring rings.
Put the spring ring upper parts 7 and 9 with mounted pads manually to the
rotor col-
lar.
Note
Lubricate the running surfaces of the bearing shells and pads with a smal
quantity
of lube oil. Make sure to keep all components absolutely clean.
12.3.2 Installing the thrust bearing, upper part

Arrange the tools according to Fig. 12-3 and carefully lower the upper
part 3.
1604 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
WARNING
Suspended Load
area.
Caution
During assembly the components of the bearing must be installed at the correct
location. See the markings on the components applied at disassembly.
Align the bearing upper part 3 with the lower part 2 using the taper pins 5,
refer to
Fig. 12-3.
Put the hexagon head bolts 4 complete with locking washers 6 Document
into the bearing upper part and tighten to the values given in HTGD 630 147
document.
en HTGD 693 000 V0140 A

1605
13
4
4
12
6
7,8
3
11
9,10
BLNL0202_
A2459

1 Bearing pedestal lower part 8 Set of pads
2 Thrust bearing, lower part 9 Spring ring
3 Thrust bearing, upper part 10 Set of pads
4 Hexagon head bolt 11 Locking plate
5 Taper pin 12 Countersunk screw
6 Locking washer 13 Eyebolt
7 Spring ring 14 Shackle
Fig. 12-3 Installing the thrust bearing, upper part
1606 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
12.4 Check measurements after installing the bearing

12.4.1 Bearing clearances
Check the bearing clearances according to the test certificate. Test
certificate
HTGD 667
273
Note
To measure the axial clearance of the bearing use the jacking oil system.
Make
sure to isolate the jacking oil system when the measurements have been
taken.
en HTGD 693 000 V0140 A

1607
12.4.2 Rotor position

Check the radial and axial position of the rotor with regards to Test
certificate
the bearing pedestal. Re-adjust if required. HTGD
667 274
12.5 Inserting the thermocouples

Insert the thermocouples 3, 4 and 5 and re-connect them in accordance with
the
markings of the KKS designations, refer to Fig. 12-4.
1
3
4
5
BLNS0203_
A2458

1 Cable clamps 4 Thermocouple radial
lower shell
2 Terminal box 5 Thermocouple axial
upper shell
3 Thermocouple axial upper shell
Fig. 12-4 Arrangement of the thermocouples
12.6 Installing the oil shield lower parts

Install the oil shield lower parts 1, refer to Fig. 12-5. Do not at this
step fully tighten
the hexagon head bolts 3.
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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
12.7 Installing the shaft position monitor

Mount the complete shaft position monitor part 2 with hexagon head bolts in
the
bearing pedestal, refer to Fig. 12-5.
Check and adjust the axial clearance of the shaft position Data
sheet
monitor, refer to the test certificate. HTGD
667 183
1
FIG 06
BLNB0202_
A2457

1 Oil shield lower part 3 Hexagon head bolt
2 Shaft position monitor
Fig. 12-5 Installing the oil shield lower parts

en HTGD 693 000 V0140 A
1609
12.8 Re-installing the bearing pedestal upper part

12.8.1 Preparations
Screw the elongation studs 3 into the parting flange of the bearing
pedestal lower
part 1, refer to Fig. 12-6.
Remove the cover from the lube oil supply.
Caution
Check to see that the lube oil supply is correct. Keep all parts that come
into con-
tact with lube oil very clean.
12.8.2 Lifting into place the upper part

Lift the bearing pedestal upper part 2 with the hoisting equipment and
keep it in the
horizontal position with chain hoists, refer to Fig. 12-6.
Align the bearing pedestal upper part 2 with the elongation studs 3 in the
bearing
pedestal lower part 1 and lower it carefully.
Note
Make sure during lowering that the oil shield in the upper part and the
threads of
the elongation studs in the lower part are not damaged.
Caution
Make sure that the load is correctly secured. Keep the upper part
horizontal when
lowering.
WARNING
Suspended Load
danger
area.
Align the bearing pedestal upper part 2 with the lower part 1 using the
taper pins 8 .
1610 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
Tighten the hexagon socket nuts 4 and mount the covers 5,

Document
refer to the values of document.
HTGD 630 147
5 9
4
8
6
2
FIG 04
7
3
BLNA0401_
A2463

1 Bearing pedestal lower part 6 Oil shield upper part
2 Bearing pedestal upper part 7 Jack screw
4 Hexagon socket nut 9 Shackle
5 Cover
Fig. 12-6 Lifting into place the bearing pedestal upper part
en HTGD 693 000 V0140 A

1611
12.9 Lifting the rotor turning gear into place

Note
Read the rotor turning gear type WDE6016 manual. HTGD 691
883
V9000
Put the taper pins in the flange of the rotor turning gear.
Caution
Make sure when lowering the rotor turning gear that the gearwheel of the
rotor
turning gear is in the disengaged position. This will prevent the teeth of
the gear-
wheel coming in contact with the turbine rotor gearwheel.
Lift the rotor turning gear 2 using hoisting equipment 4 and align it
carefully with the
bearing pedestal upper half 1, refer to Fig. 12-7.
Loosely fit the hexagon head bolts 3 and locate the turning gear accurately.
Tighten the hexagon head bolts 3 refer to the tightening specification.
Remove the hoisting equipment.
Refer to Rotor Turning Gear documentation for final assembly instructions.
1612 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
6
3
4
5 2
1
801
BLNA0402_
A2467

1 Pedestal housing upper half 5 Lifting eye
2 Rotor turning gear 6 Cover
3 Hexagon socket head bolt 801 Taper pin
4 Hoisting equipment
Fig. 12-7 Lifting the rotor turning gear into place
12.10 Adjusting the oil shields

Adjust the oil shield upper and lower parts and fully tighten them, refer
to the test
certificate.
Record the adjusted dimensions of the oil shields in the test Data
sheet
certificate. HTGD
499 343
HTGD
667 267
en HTGD 693 000 V0140 A

1613
12.11 Connecting the oil supply of the turning gear

Remove the caps 10 from the oil pipes, refer to Fig. 12-8.
Refit the turning gear oil pipes 4 and secure with clamps and locking
plates.
10
2 4
BLNJ0202_
A2466

1 Rotor turning gear 4 Oil pipe
2 Bolted joint 10 Pipe cap
Fig. 12-8 Connecting the oil supply
1614 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020 -
Block
12.12 Installing the instruments

12.12.1 Measured value transmitter
Refit the transmitters for measuring the vibrations, phase angle and
speed, refer to
Fig. 12-9.
12.12.2 Electrical connections

Re-connect electrically the instruments and thermocouples at the bearing
pedestal,
and rotor turning gear, refer to the markings applied during disassembly.
en HTGD 693 000 V0140 A

1615
12.12.3 Checking the adjustments

Check and adjust the axial clearance of the shaft position Data
sheet
monitor and the radial clearance of the phase and vibration HTGD
667 183
transmitters, refer to the test certificate.
Check and adjust the radial clearance of the speed transmit- Data
sheet
ters, refer to the test certificate. HTGD
499 345
Replace access covers when checks are complete.

1
2,3
8 5
6
7
4
BLNS0204_
A2462

1 Assembly speed sensor 5 Support
2 Phase angle measurement 6 Support
3 Shaft vibration measurement 7 Absolute expansion
measurement
4 Support 8 Casing vibration
measurement
1616 HTGD 693 000 V0140 A

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MAA10/MAC10 -
HTGD693011V9020 -
Turbine Block
12.13 Refit the coupling cover.

Refit the coupling cover upper and lower parts with hexagon head screw 2,
hexagon
head nut 5 and washer 3, refer to Fig. 12-10.
BLNA0403_
2,3,5
A2464

1 Coupling cover, lower part 4 Coupling cover,
upper part
2 Hexagon head screw 5 Hexagon head nut
3 Washer
Fig. 12-10 Refiting the coupling cover
12.14 Connecting the oil supply to the bearing pedestal

Note
This step is only required if a blanking plate was installed to allow for
operation of
the jacking oil system during maintenance.
12.14.1 Removing the plug

Loosen the hexagon head bolts 10 at the plug 11 and pull out the plug
using hoist-
ing equipment, refer to Fig. 12-11.
Remove the blanking plate 13 and install the bearing oil orifice
8. Put the blanking
plate 13 in the tool cabinet.
en HTGD 693 000 V0140 A

1617
12.14.2 Re-installing the plug with orifice

Install the plug 11 using hoisting equipment.
4 5
10 6
9
3
13
11
7
12
BLNC0202_
A2465

1 Bearing pedestal, lower part 8 Orifice
2 Seal 9 Cylindrical
pin
3 Flange 10 Hexagon head
bolt
4 Hexagon head bolt 11 Plug
5 Eyebolt 12 Vibration
transmitter
6 Cylindrical pin 13 Blanking
plate
7 Socket head screw
Fig. 12-11 Refiting the plug with orifice
1618 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
12.15 Final work and final checks

Precondition
Note
The bearing pedestals and the turbine are in the operating position.
12.15.1 Check measurements

Check and record the clearances of the hold-down claws, refer Data
sheet
to the test certificate. HTGD
499 340
Check and record the clearances of the vertical keyway of the Data
sheet
turbine, refer to the test certificate. HTGD
667 277
Check and record the clearances of the hold-down devices of Data

sheet
the turbine, refer to the test certificate. HTGD
667 276
Check the deflection line of the shaft train of the turbine, refer Data
sheet
to the test certificate. 1BSE
501 730
Check and record the clearances of the axial fixing system of Data
sheet
the turbine, refer to the test certificate. HTGD
667 275
12.15.2 Final remarks
Note
Tighten and secure all screws and bolts without recorded
Document
prestress according to document. HTGD
630 147
Note
Re-connect all thermocouples and instruments of the bearing pedestal,
refer to the
markings applied during disassembly and make a functional test.
The lube oil, jacking oil and turning gear systems are again in operation
and oper-
ate correctly.
Clean all tools used for maintenance, check their completeness and put
them in the
tool cabinets.
en HTGD 693 000 V0140 A
1619
Blank page
1620 HTGD 693 000 V0140 A en

MAA10/MAC10 - HTGD693011V9020 -
CHAPTER 13
FINAL WORK
en HTGD 693 000 V0140 A 1621

13 FINAL WORK
13.1 Adjusting the operating positions

Make sure that all components are again in the operating position. Remove
assem-
bly aids and tools.
Re-install all dismantled components and parts at their location and
original position,
in accordance with the markings applied during disassembly.
Pre-tension and secure all bolted joints in accordance with the
instructions, manufac-
turer's guidelines, data sheets and test certificates.
� Flange joints of the bearing pedestals
� Flange joints of the turbine inner and outer casings
� Flange joint of the cover flange at the compensator.
13.2 Pipelines and pipe unions

Re-install pressure-tight all pipelines.
Replace the bolted joints if the locking welds had to be ground off.
Secure all bolted joints according to instructions.
13.3 Expansion joint

The Superseals have been glued to the exhaust steam collar and the
expansion joint
neck according to procedure and the expansion joint has been assembled as
in-
structed.
Note
The base plates have been installed correctly underneath the slanted split
plane
surfaces of the cover flange. Make sure that it is assured that the
expansion joint
can be compressed sufficiently to seal around the gap.
The cover over the top half of the connection turbine - expansion joint
has been as-
sembled to protect the expansion joint.
13.4 Power supply

13.4.1 Connecting the auxiliary systems
Re-connect correctly all auxiliaries. Replace worn, damaged or broken
cables.
� Lube oil supply
� Control oil supply
� Jacking oil supply
1622 HTGD 693 000 V0140 A

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MAA10/MAC10 - HTGD693011V9020
-
Turbine Block
� Rotor turning gear supply.
Note
Check the power consumption of all direct and alternating current motors
of the
pumps and the direction of rotation.
Pre-charge again the bladder or diaphragm accumulator with nitrogen.

Re-connect the thermocouples for measuring the bearing metal and oil drain
tem-
peratures and make a functional test.
Re-connect the instruments for the vibration, phase and differential
expansion
transmitters and make a functional test.
Re-connect the control elements of the rotor turning gear and make a
functional test.
Re-connect the grounding devices and the busbars to the foundation and
make a
functional test.
13.4.3 Valve actuators

Re-connect the proportional and directional control valves of the valve
actuators and
make a functional test.
Re-connect the limit switches and stroke transmitters of the valve
position transmis-
sion and make a functional test.
13.4.4 Turbine
Re-connect the startup probe and the temperature sensors for temperature
supervi-
sion and make a functional test.
13.5 Lube oil supply to the bearing pedestals

Caution
Remove the blank flanges in the lube oil supply pipes and replace them by
feed
orifices.
Start again the lube oil and jacking oil supply systems to the turbine
bearings.
Note
Check with dial gauges whether the rotor has been lifted at least 0.02 mm
with the
jacking oil system in operation.
en HTGD 693 000 V0140 A
1623
13.6 Functioning of the valve actuators

After re-assembling the actuators and connecting them with the valves,
check the
functioning and adjustment of the valve strokes, electric equipment and
hydraulic
supply.
13.6.1 Stop valve actuators
13.6.2 Control valve actuators
13.7 Auxiliary systems

Re-connect the seal air, gland steam and auxiliary steam systems and make
a func-
tional test.
13.8 Insulation and enclosure

13.8.1 Insulation
If a completely or partly new insulation has to be applied, follow
strictly the relevant
drying and application instructions.
Make sure that insulating mats which are fastened to the casing lower
parts have
particularly good contact.
Note
Cover adequately the area of the movable parts if a new insulation has to
be ap-
plied near the valve and valve actuator.
Clean once again, if necessary.
13.8.2 Sound-absorbing enclosure

When re-assembling the sound-absorbing enclosure, follow strictly the
manufac-
turer's instructions for installing the roof and wall support parts, roof
and wall panels
and guard rails.
13.9 Checks and final work

Clean the tools and assembly aids and store them in the tool cabinets.
Clean all provisional covers and hoods, used for maintenance, and store
them at the
appropriate places.
Check whether all test certificates have been completed and initialled.
Send a copy of the test certificates to the ALSTOM Service Department.
HTGD693011V9020
1624 HTGD 693 000 V0140 A

en
MAA10CT005/010- HTGD693029V9001 -
Temperature Sensor
MAA10CT005/010-
HTGD693029V9001 -
Temperature Sensor
en HTGD 693 000 V0140 A 1625

Revision History
total :
- - (6)
1626 HTGD 693 000 V0140 A en

MAA10CT005/010- HTGD693029V9001 -
Temperature Sensor
Contents
1
DISMANTLING........................................................................
.........................................................1629
2 RE-
ASSEMBLY...........................................................................
.....................................................1629
en HTGD 693 000 V0140 A

1627
WP4110 & WP4140
Figures
Fig. 1 Temperature
sensor ............................................................................
.......................... 1630
Synopsis of the test certificates
1628 HTGD 693 000 V0140 A

en
MAA10CT005/010- HTGD693029V9001 -
Temperature
Sensor
1 DISMANTLING
Remove the cover 18 according to Fig. 1 and disconnect the thermocouple 2 at
the
terminal 20.
Record the connections for the later re-assembly.
Loosen the hexagon head bolts 11 and pull off the connection piece 6.
Loosen the drain connection 9 from the flange 5.
Unscrew the hexagon recess nuts 10 and remove very carefully the flange 5 with
in-
serted thermocouple 2.
Note
Observe the pretension of the compression spring 4.
Remove the compression spring 4 and spring disk 3.

Screw an elongation stud 7 into the toggle lever 1 and pull it out.
2 RE-ASSEMBLY
Insert the toggle lever 1 with an elongation stud 7 into the turbine casing.
Insert the spring disk 3 and the compression spring 4 into the turbine casing.
Fit the flange 5 and insert carefully thermocouple 2 into the toggle lever 1.
Fasten the flange 5 with hexagon recess nuts 10 and tighten it Document
according to the values given in the document. HTGD 630
147
Screw the connection piece 6 with the hexagon head bolts 11 to the flange 5
and se-
cure the bolts with lock washers 12.
Connect the thermocouple 2 according to the markings from the disassembly at
the
terminal 20 and mount the cover 18 with gasket 19.
Check the proper re-installation of the temperature sensor ac- Test
certificate
cording to the test certificate and make a functional test. 1BSE 501
728
Fasten the drain connection 9 leak-tight to the flange 5.
en HTGD 693 000 V0140 A

1629

1 Toggle lever 12 Lock washer
2 Thermocouple 13 Holder
3 Spring disk 14 Hexagon head bolt
4 Compression spring 15 Washer
5 Flange 16 Cylindrical head screw
6 Connection piece 17 Washer
7 Elongation stud 18 Cover
8 Screw plug with seal 19 Gasket
9 Drain connection 20 Terminal
10 Hexagon recess nut 100 Turbine outer casing
Fig. 1 Temperature sensor
HTGD693029V9001
1630 HTGD 693 000 V0140 A en

MAA12 - HTGD690520V9008 -
Swing Arm Supports
MAA12 - HTGD690520V9008 -
Swing Arm Supports
en HTGD 693 000 V0140 A 1631

Revision History
total :
- - (8)
1632 HTGD 693 000 V0140 A en

MAA12 - HTGD690520V9008 -
Swing Arm Supports
Contents
1
PURPOSE............................................................................
............................................................1635
OPERATION ...................................................................1636
3
GENERAL ...........................................................................
.............................................................1636
4 LOCKING THE SWING ARM
SUPPORTS...........................................................................
...........1637
5 EXCHANGING THE BELLEVILLE
SPRINGS ...........................................................................
......1637
5.1 Dismantling the swing arm

supports .................................................................... 1637
5.2 Re-assembling the swing arm
supports............................................................... 1637
6 ADJUSTING THE OPERATING
POSITION ..........................................................................
..........1638
en HTGD 693 000 V0140 A

1633
& WP4140
Figures
Fig. 1 Swing arm support in operating

position .......................................................................
1635
Fig. 2 Swing arm support
locked ............................................................................
................. 1636
Test certificates
1634 HTGD 693 000 V0140 A

en
MAA12 - HTGD690520V9008 -
Swing Arm
Supports
1 PURPOSE
Due to their size, deflection and weight, the steam turbine valve blocks,
flanged to
the turbine casings, must be supported.

1 Guide rod 8 Washer
2 Guide bushing 9 Headless screw
3 Spherical seat 10 Hexagon head bolt
4 Bolt 11 Hexagon nut
5 Support base 12 Washer
6 Belleville spring 13 Valve block
7 Socket head screw 14 Foundation
Fig. 1 Swing arm support in operating position
en HTGD 693 000 V0140 A

1635

The valve blocks are supported by double-hinged and thermally flexible swing
arm
supports, which rest on the foundation. The valve weight is accommodated by
a
spring assembly, consisting of several laminated Belleville springs.
3 GENERAL
When dismantling turbines and lifting off the turbine casing upper halves,
the flanged
joint of valve block and turbine casing must be loosened. Before loosening
this con-
nection, the spring assembly of the swing arm supports must be locked. The
swing
arm supports must not be dismantled for this purpose.

2 Spring bushing 10 Hexagon head bolt
4 Bolt 11 Hexagon nut
5 Support base 12 Washer
6 Belleville spring 14 Foundation
Fig. 2 Swing arm support locked
1636 HTGD 693 000 V0140 A

en
MAA12 -
HTGD690520V9008 -
Swing Arm
Supports
4 LOCKING THE SWING ARM SUPPORTS

The spring assembly is locked by screwing down the hexagon head bolts 10 and
hexagon nuts 11 according to Fig. 2.
5 EXCHANGING THE BELLEVILLE SPRINGS

Starting point
The spring assembly is locked according to Fig. 2.
5.1 Dismantling the swing arm supports

Support provisionally the valve block vertically on the foundation and secure
it in this
position.
Loosen the headless screws 9 at the guide rod 1 and the valve block 13
according to
Fig. 1.
Remove the socket head screw 7 from the spherical seat 3 and screw the
spherical
seat up to the stop into the valve block 13.
Loosen the hexagon head bolts 10 and remove them with the washers 12 and
bolts
4.
Remove the guide rod 1 with the Belleville springs 6 from the guide bushing
2.
Note
Check the Belleville springs for cracks and replace them, if necessary.
5.2 Re-assembling the swing arm supports

Insert the guide rod 1 with the Belleville springs 6 in the guide bushing 2
according to
Fig. 1.
The lamination of the Belleville springs is specified in the data Data
sheet
sheet. HTGD 667
231
Adjust the pretension "Lv" of the spring assembly accord-ing to the data
sheet by re-
adjusting the spherical seat 3.
Screw the socket head screw 7 into the spherical seat 3.
Drill the spherical seat for the headless screw 9 after the necessary re-
adjustment
and secure it against turning.
Fit the bolts 4 with the hexagon head bolts 10, washers 12 and hexagon nuts
11 ac-
cording to Fig. 2.
Adjust dimension "A" with the socket head screw 7 at the Data
sheet
spherical seat 3 according to the data sheet and Fig. 1 and se- HTGD 667
231
cure it with the headless screw 9.
en HTGD 693 000 V0140 A

1637
6 ADJUSTING THE OPERATING POSITION

Screw down the hexagon head bolts 10 according to Fig. 1, Data sheet
adjust dimension "B" according to the data sheet and secure HTGD 667 231
the bolts with the hexagon nuts 11.
Check the pretension "Lv" of the spring assembly and re-adjust, if

necessary.
HTGD690520V9008
1638 HTGD 693 000 V0140 A

en
MAC10 - HTGD690082V9000 -
Rupture Diaphragm
MAC10 - HTGD690082V9000 -
Rupture Diaphragm
en HTGD 693 000 V0140 A 1639

Revision History
total :
- - (6)
1640 HTGD 693 000 V0140 A en

MAC10 - HTGD690082V9000 -
Rupture Diaphragm
Contents
1
PURPOSE............................................................................
............................................................1643
2
ASSEMBLY ..........................................................................
............................................................1644
3 OPERATION AND
MAINTENANCE .......................................................................
.........................1644
en HTGD 693 000 V0140 A

1641
WP4140
Figures
Fig. 1-1 Arrangement of the rupture

diaphragm ......................................................................
1643
Test certificates
1642 HTGD 693 000 V0140 A

en
MAC10 - HTGD690082V9000 -
Rupture Diaphragm
1 PURPOSE
The rupture diaphragms protect the turbine exhaust casings and the condensers
against overpressure. They are planned weak points that break at a defined
pres-
sure caused by inadmissible operating conditions.
When the rupture diaphragm breaks, a certain cross-section area is cleared
through
which steam escapes from the turbine, thus reducing the overpressure.
The main parts of the rupture diaphragms are special lead plates which during
nor-
mal operation rest steam-tight against the vacuum supports.

1 Cover 5 Flange
2 Lead plate 6 Grating
3 Vacuum support 7 Hexagon head bolt
4 Seal 8 Hexagon head bolt
Fig. 1-1 Arrangement of the rupture diaphragm
en HTGD 693 000 V0140 A

1643
2 ASSEMBLY
12
MAC10 BP010
When installing the rupture diaphragm, make sure that the cover 1, lead
plate 2 and
support 3 are mounted with the convex sections towards the outside (see
Fig. 1).
Note
The cover, lead plate and support must always be replaced as one unit
during re-
quired repairs.
The flange of the turbine outer casing or the condenser neck must be
provided with a
seal 4 to ensure sealing towards the atmosphere.
Tighten the hexagon head bolts 7 in accordance with the data Data
sheet
sheet. HTGD
630 147
3 OPERATION AND MAINTENANCE

Caution
Inspect thoroughly the surface of the cover after assembly. Replace the
above
mentioned parts immediately in the case of sharp-edged damage like
scratches or
notches.
Except for this check, the rupture diaphragm is maintenance-free.
HTGD690082V9000
1644 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0001A -
Low Pressure Butterfly-Type Valve
MAC31- HTGD691780V0001A -
en HTGD 693 000 V0140 A 1645

Revision History
total :
- - (10)
1646 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0001A -
Contents
1 DESIGN AND
APPLICATION .......................................................................
...................................1649
2 TECHNICAL
DESCRIPTION .......................................................................
....................................1649
2.1 Steam
data...............................................................................
............................ 1649
2.2 Stop and control
valves.............................................................................
........... 1649
2.3 Valve
construction.......................................................................
......................... 1649
2.4 Stop and control valve
actuators..........................................................................
1650
2.4.1
Design ............................................................................
......................... 1650
2.4.2 Electrical connections for stop valve
actuator ......................................... 1650
2.4.3 Electrical connections for control valve
actuator ..................................... 1651
2.4.4 Pressure
medium ............................................................................
........ 1651
2.5 Pilot control for the stop valve
actuator................................................................ 1651
2.5.1 Construction and
function........................................................................
1651
2.5.2 Stroke
test ..............................................................................
................. 1651
2.5.3 Hydraulic
connections .......................................................................
...... 1651
2.6 Pilot control for the control valve
actuator............................................................ 1652
2.6.1 Construction and
function........................................................................
1652
2.6.2 Safety
function...........................................................................
.............. 1652
2.6.3 Hydraulic
connections .......................................................................
...... 1652
2.7 Steam
strainer...........................................................................
........................... 1652
2.7.1
Construction ......................................................................
...................... 1652
2.7.2 Mode of
assembly ..........................................................................
......... 1653
2.8 Hinged
supports...........................................................................
........................ 1653
en HTGD 693 000 V0140 A

1647
Dimensional drawing of low pressure valve
1648 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0001A
-
Low Pressure Butterfly-
Type Valve
1 DESIGN AND APPLICATION

Low-pressure butterfly-type valves are mounted on the steam turbines for
secondary
and third steam admission for superheated and saturated LP steam. Looking in
the
direction of steam flow, the valve consists of a stop valve, a control valve
and a
steam strainer.
The valves may only be mounted horizontally in the pipeline. In front of the
stop
valve, a straight pipe spool with a length of at least twice the valve DN has
to be in-
stalled.
Both valves are bolted together and also bolted to the steam strainer and the
secon-
dary of third steam pipe. They are equipped with drain nozzles.
2 TECHNICAL DESCRIPTION
2.1 Steam data
DN of valve Pressure [Mpa] max. Temperature [�C]
250, 350, 500 1.0 300
700 0.8 300
During the leak tests the valves and the steam strainer are submitted to a
pressure
test of 1.5 times the design pressure. The test medium is water.
2.2 Stop and control valves

The stop valve is on ON/OFF valve, controlled by the turbine safety system.
The control valve regulates the steam flow to the turbine according to the
quantity
specified by the turbine controller. The valve remains in the position
corresponding to
the input signal.
In case of intolerable operating conditions of the turbine, both valves
intercept the
steam flow. This provides double safety against intolerable operating
conditions. The
closing time of the valves is max. 300 ms.
2.3 Valve construction

The stop valve and the control valve are identical, double eccentrically
mounted but-
terfly-type valves with unidirectional tightness.
Due to the eccentricity of the disc/shaft the steam force acts on the disc as
a closing
force. The closed position of the disc is determined by a stop in the
actuator. For
safety reasons an additional stop is integrated in the valve housing
The tightness in closed position is achieved by metallic seals into which the
disc pro-
trudes.
en HTGD 693 000 V0140 A
1649
The disc seals are hard-faced. This hard-facing prevents the disc from
erosion and
damages.
2.4 Stop and control valve actuators

2.4.1 Design
The stop and control valves are operated by identical actuators, type RHM.
The ac-
tuator sizes are defined in the table below and have various accessories
according
to their function.
DN of valve Actuator RHM
250 250 / 150
350 650 / 200
500 1500 / 250
700 3000 / 320
The RHM actuators consist mainly of the power piston with damping in
closing direc-
tion, the main casing and the Belleville spring stack.
In the main casing the linear movement is converted into rotation via a
rack and a
pinion.
The actuators are designed for a working pressure of 4 MPa in the safety
system
and open the valves hydraulically. The closing "fail-safe" motion is
effected by spring
force.
The 90� open position of the stop valve is given by a stop in the actuator.
The valve
positions are indicated by proximity sensors.
The open position of the control valve is realised by the input signal via
the propor-
tional control valve and the actuator. A stop in the actuator limits the
open position at
95�.
The valve position is monitored by an inductive angle transmitter, directly
mounted to
the valve shaft.
The actuators are equipped with a pressure measuring connection for the
pressure
below the actuator piston. The main hydraulic connections are mounted to
the pilot
control system.
2.4.2 Electrical connections for stop valve actuator

� Directional control valve for stroke test el11 solenoid A
� Directional control valve for stroke test el12 solenoid B
� Proximity sensor, position "closed" el14
1650 HTGD 693 000 V0140 A

en
MAC31-
HTGD691780V0001A -
Low Pressure
Butterfly-Type Valve
� Proximity sensor, position "open" el15
2.4.3 Electrical connections for control valve actuator

� Proportional control valve, solenoid B, el21
� Proportional control valve, solenoid A, el22
� Stroke transmitter el23
� Inductive angle transmitter el24
2.4.4 Pressure medium

The lubricating and control oils for turbines or flame-resistant hydraulic
fluids, ac-
cording to separate specifications, may be used for feeding the actuators.
2.5 Pilot control for the stop valve actuator

2.5.1 Construction and function
The pilot control system is flanged to the stop valve actuator and consists
mainly of
the discharge amplifier, the oil collector and the directional control
valve for stroke
testing.
With sufficient pressure in the safety system, the stop valve opens; it
closes if the
pressure in the safety system drops below a set value or if the system is
discharged.
The discharge amplifier opens and the pressure medium from the actuator
piston
chamber flows into the oil collector. A connection is provided for the
sheet metal
channel for fire protection.
2.5.2 Stroke test

For stroke testing, the directional control valve is activated in such a
manner that the
actuator piston chamber is connected directly with the oil collector; the
stop valve
closes slowly: If the 0� position of the "full stroke test" is reached, the
solenoid valve
is deactivated automatically via the proximity sensors and the valve opens
again.
2.5.3 Hydraulic connections

� Safety system /80
� Drain /65
en HTGD 693 000 V0140 A

1651
2.6 Pilot control for the control valve actuator

2.6.1 Construction and function
The pilot control system is flanged to the control valve actuator and
consists mainly
of the proportional control valve with integrated stroke transmitter, the
power ampli-
fier, the discharge amplifier and the oil collector.
The proportional valve with the pertinent power amplifier regulates, via
the pressure,
the position of the actuator piston according to the input signal of 4...20
mA, which
corresponds to the desired opening of 0�...90� of the control valve.
The control can be configured at the power amplifier. If the pressure in
the safety
system drops below a preset value, or if the system is discharged, the
discharge
amplifier opens and the pressure medium below the actuator piston
discharges into
the oil collector; the control valve closes. A connection is provided for
the sheet
metal channel for fire protection.
2.6.2 Safety function

An orifice is built into the pilot valve for inlet and discharge. The inlet
orifice prevents
dry running of the pilot valve system and the actuator with closed control
valve. The
discharge orifice ensures slow closing of the control valve in case of a
failure of the
proportional control valve.
2.6.3 Hydraulic connections

� Safety system /81
� Drain /66
2.7 Steam strainer

2.7.1 Construction
The body is an eccentric strainer basket in form of a perforated plate with
welded-on
fine screen, which deflects the steam flow by 90�. The strainer acts as
flow equalizer
and permits a uniform twist-free steam flow to the turbine. The fine screen
protects
the turbine form solid particles.
As the steam flows from the inside to the outside, the solid particles are
collected at
the inside of the strainer and can easily be removed.
A suspension device is supplied for the strainer.
1652 HTGD 693 000 V0140 A

en
MAC31-
HTGD691780V0001A -
Type Valve
2.7.2 Mode of assembly

The steam strainer entry is normally equipped with a weld-neck flange and
mounted
directly to the control valve, the exhaust nozzle is welded directly to the
secondary or
third steam pipe. The steam strainer can also be welded into the pipeline
at any point
between the control valve and the turbine. In this case the entry of the
steam strainer
is not equipped with a weld-neck flange. The steam pipeline always has to
run hori-
zontally. The steam exhaust normally points downwards, in exceptional cases
up-
wards.
2.8 Hinged supports

The steam valve is supported on the foundation by adjustable supports.
There are 2
supports on the left and the right side of the valve between the 2
butterfly valves and
at the side of the steam strainer.
The hinged supports rest with base plates on the foundation and are mounted
to the
valves and the steam strainer by double latches. The bottom and top
connections
are equipped with adjustable cardan joints for compensating the turbine and
pipeline
expansions.
HTGD691780V0001A
en HTGD 693 000 V0140 A

1653
Blank Page
1654 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0101D -
Technical Instructions
MAC31- HTGD691780V0101D -
en HTGD 693 000 V0140 A 1655

Revision History
Document Pages
total :
A New content
-
B Modification of fig. 8, 99-02-24
-
C Mod. of pos.no. for the thrust collar in capitel 3.1.4, 01-10-25 / Sa
22
D Chapter 1, DISASSEMBLY AND ASSEMBLY GUIDELINES, 05-06-01
-
- -
(38)
1656 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0101D -
Contents
1 DISASSEMBLY AND ASSEMBLY

GUIDELINES.........................................................................
...1662
1.1
Introduction ......................................................................
.................................... 1662
1.2
General ...........................................................................
..................................... 1663
1.2.1 Safety
Precautions .......................................................................
........... 1663
1.2.2 Standard Engineering
Practices.............................................................. 1664
1.2.3 Technical Knowledge
Required............................................................... 1664
1.2.4 Replacement
Parts..............................................................................
.... 1665
1.2.5 Tools and Lifting
Devices ........................................................................
1665
Checks ..........................................................................
1666
1.2.7
Reassembly.........................................................................
.................... 1666
1.2.8
Pipework...........................................................................
....................... 1667
2 INITIAL
ASSEMBLY...........................................................................
..............................................1670
2.1 As-delivered
condition..........................................................................
................ 1670
2.2 Welding into the
pipeline...........................................................................
........... 1670
3 ADJUSTMENT OF THE HINGED
SUPPORTS...........................................................................
....1672
4
MAINTENANCE .......................................................................
........................................................1674
4.1 Valve
seals..............................................................................
............................. 1674
4.1.1 Dismantling of the
actuators.................................................................... 1674
4.1.2
Checks ............................................................................
........................ 1675
4.1.3 Disassembly of the valve
seals ............................................................... 1675
4.1.4 Re-installation of the valve
seals............................................................. 1675
4.1.5 Re-assembly of the
actuators.................................................................. 1676
4.2
Bearings...........................................................................
.................................... 1678
4.2.1 Dismantling of the drive
shaft .................................................................. 1678
4.2.2 Dismantling of the bearing
bushings ....................................................... 1678
4.2.3 Re-assembly of the bearing
bushings ..................................................... 1678
4.2.4 Re-assembly of the drive
shaft................................................................ 1678
4.2.5 Re-assembly of the drive-end
bearing .................................................... 1679
4.2.6 Re-assembly of the non-drive-end
bearing ............................................. 1679
4.2.7 Re-assembly of the
actuators.................................................................. 1679
4.3 Re-installation of the valve in the
pipeline............................................................ 1679
4.3.1 Screwed
joints ............................................................................
............. 1679
4.3.2 Re-connection of the
valve...................................................................... 1680
5 MAINTENANCE OF THE
ACTUATORS .........................................................................
................1680
en HTGD 693 000 V0140 A

1657
& WP4140
5.1 Dismantling of the

actuators .........................................................................
....... 1680
5.2 Re-assembly of the
actuators .........................................................................
..... 1681
5.3 Pilot
controls ..........................................................................
.............................. 1684
5.3.1 Pilot control of control
valve .................................................................... 1684
5.3.2 Pilot control of stop
valve ........................................................................ 1686
5.3.3 Terminal
box ...............................................................................
............ 1688
6 CLEANING OF THE STEAM
STRAINER ..........................................................................
............. 1690
7 GENERAL MAINTENANCE OF THE
VALVE .............................................................................
.... 1691
1658 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0101D -
Figures
Fig. 1 Tightening torques for flange joints of intermediate

piepe ............................................. 1670
Fig. 2 Intermediate
pipe ..............................................................................
............................. 1671
Fig. 3 Adjustment of hinged
supports ..........................................................................
............ 1672
Fig. 4 Hinged
support ...........................................................................
................................... 1673
Fig. 5 Tightening torques for headless screws of
valve........................................................... 1675
Fig. 6 Butterfly-type
valve .............................................................................
........................... 1676
Fig. 6 Butterfly-type
valve .............................................................................
........................... 1677
Fig. 7
Actuator ..........................................................................
............................................... 1682
Fig. 7
Actuator ..........................................................................
............................................... 1683
Fig. 8 Pilot control of control
valve..............................................................................
............. 1684
Fig. 8 Pilot control of control
valve..............................................................................
............. 1685
Fig. 9 Pilot control of stop
valve..............................................................................
................. 1686
Fig. 9 Pilot control of stop
valve..............................................................................
................. 1687
Fig. 10 Terminal
box ...............................................................................
................................. 1688
Fig. 10 Terminal
box ...............................................................................
................................. 1689
Fig. 11 Steam
strainer ..........................................................................
................................... 1690
Fig. 11 Steam
strainer ..........................................................................
................................... 1691
Fig. 12 Tightening torques for flange joints of steam
strainer.................................................. 1691
en HTGD 693 000 V0140 A

1659
Dimension drawing of valve
1660 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0101D -
CHAPTER 1
DISASSEMBLY AND ASSEMBLY GUIDELINES
en HTGD 693 000 V0140 A 1661

1 DISASSEMBLY AND ASSEMBLY GUIDELINES

1.1 Introduction
complied with
document.
Danger,
Warning, Caution, Note and Parts List Reference. These symbols are used in
the fol-
lowing circumstances:
DANGER
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury. This signal word is to be
limited
to the most extreme situation.
WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided,
may
result in minor or moderate injury. It may also be used to alert
against unsafe practices.
Caution
Note
1662 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0101D
-
Type Valve
Technical
Instructions
12
Informs the user of the relevant Parts List where further details
of
each component can be found.
1.2 General
1.2.1 Safety Precautions
The following general safety precautions apply to both dismantling and
reassembly
procedures. Throughout the maintenance text, where applicable, a specific
warning
and/or caution is inserted prior to the affected procedural step.
Maintenance personnel should also comply with the local/regional safety
require-
ments.
Prior to starting maintenance, ensure that the turbine and all interfacing
systems are
shut down, drained and made safe as detailed in the Operation Manual.
Ensure that the steam turbine is stationary, because - on single-shaft
units - even
with the clutch coupling disengaged, the possibility exists of inadvertent
engagement
of the coupling.
When handling thermal insulation mats, always wear approved face masks and
gloves.
When using cleaning solvents, always wear approved protective goggles,
gloves and
clothing.
When operating welding equipment or grinding machines, always wear approved
procedures are
observed and all personnel not involved in these operations are clear of
the immedi-
ate area.
When using the special hydraulically operated tools, ensure that the
manufacturers
recommendations for the specific fastener are followed. Do not lean over
the tool
when pressure is applied.
� use only the approved lifting devices and operate them in accordance with
the
� ensure that the load is correctly secured
� Do not stand under suspended load
en HTGD 693 000 V0140 A
1663
� ensure that all personnel not involved with the lifting operation are
kept clear of
the immediate area.
1.2.2 Standard Engineering Practices

Standard engineering practices, described in the following paragraphs,
should be fol-
lowed during all maintenance procedures. Knowledge of, and the correct use
of,
tools and equipment is assumed throughout.
To prevent housing deformation, loosen/tighten split-line fasteners in the
correct se-
quential order.
To prevent equipment (for example: instrumentation) against deformation or
damage
use suitable covers.
To prevent ingress of foreign objects during dismantling, seal all
pipe/housing ori-
fices with the approved maintenance covers provided, see the instruction
manual
Tools according to the manufacturer. During reassembly, remove the blank
from a
sealed pipe/casing housing immediately prior to reconnection.
On reassembly, renew all O-rings, seal rings, gaskets, safety locking
plates and
spring washers that were removed during dismantling.
On reassembly, renew all fasteners that had a locking bead weld ground off
during
dismantling.
Do not rotate the turbine rotor shaft without activating the HP jacking-oil
system or
damage may be caused to the white metal linings of the journal bearings.
Measurements and checks of the turbine max axial bearing clearance only
with the
HP jacking-oil system activated.
Measurements and checks of the turbine blade clearances are to be performed
with-
out the HP jacking-oil system activated.
After shut-down, use the rotor turning gear system to rotate the turbine
rotor shaft
until the ST set has cooled to less than 150 �C. (302 �F). Failure to do
this could re-
sult in distortion of the turbine rotor shaft.
For fasteners not listed in the Test Certificates, use standard torque
loading prac-
tices.
1.2.3 Technical Knowledge Required

Extensive technical knowledge and experience is required by personnel
tasked with
the maintenance work.
1664 HTGD 693 000 V0140 A

en
MAC31-
HTGD691780V0101D -
Type Valve
Technical
Instructions
Note
Only ALSTOM staff should do overhaul work.
All maintenance must be undertaken in accordance with the instructions
detailed in
the Operating and Maintenance Manuals.
Common site repairs require only the use of standard practices and basic
engineer-
ing knowledge.
All welding must be done only by technical staff possessing the valid
licences to per-
form such work. Where the performance or safety of the steam turbine is in
question,
consult with the ALSTOM service department.
ALSTOM assumes no liability for damage caused by defective maintenance work
or
by inadequate preventive maintenance programmes.
1.2.4 Replacement Parts

Serious damage can be incurred as a result of using replacement parts that
have not
been approved by ALSTOM. ALSTOM assumes no liability for damage caused by
the use of non-approved replacement parts.
Always check which replacement parts will be required and ensure that all
replace-
ment parts are available before starting work.
Note
When ordering spare parts, only use the identification detailed in
the rele-
vant Parts List.
1.2.5 Tools and Lifting Devices

In some cases the maintenance tasks require the use of special tools and
lifting de-
vices. Where such tools and lifting devices are required, their use is
detailed in the
relevant text and highlighted both in text and on the appropriate figure by
the symbol.
Unless stated otherwise, return all jacking screws, guide bolts, taper pins
and ap-
proved maintenance covers to the relevant tool chest after each stage of
disman-
tling/reassembly.
Taper pins should always be inserted in the housing flanges before the
flanges are
brought together. When inserting a taper pin, it should be a tight fit.
en HTGD 693 000 V0140 A
1665
Note
Exceptions from the above mentioned rule are mentioned in the
mainte-
nance instructions.
ALSTOM denies any responsibility for damages caused by the use of
un-
suitable or damaged tools or hoisting equipment.
dam-
1.2.6 Inspections and Checks

The maintenance text details the inspections and checks required during
disman-
tling/reassembly procedures and provides references to the relevant Test
Certifi-
cates.
1.2.7 Reassembly
All component parts being reassembled must:
� be clean, free of scale and solvent residues
� be fully functional
� have no cracks or mechanical damage
� have no excessive wear
Seal surfaces must be clean and free of cross-grooving and damage. If
necessary,
smooth the surfaces with an oil stone.
Immediately before reassembly, lubricate all threads, fits and contact
surfaces with
high-heat resistant lubricant. Refer to paragraph 1.4.
Always reassemble components in their original positions, noting the
alignment iden-
tifications marked on them prior to dismantling.
Make sure that all bolted joints are tightened and secured in accordance
with the in-
structions, guidelines of the manufacturer, data sheets or test
certificates.
Caution
Do not use securing wires in the steam chambers or inside

pipelines be-
cause broken wires may damage machine parts. Use other securing
methods.
1666 HTGD 693 000 V0140 A

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MAC31- HTGD691780V0101D
-
Type Valve
Technical
Instructions
1.2.8 Pipework
Seal the openings correctly and protect the flange and/or seal surfaces
from dam-
age.
Use only blanking flanges, blanking plugs, etc. to seal the openings. Never
block the
pipe lines with cleaning cloths or similar materials.
After the pipe lines and hoses have been cleaned and sealed, ensure that
they are
correctly identified and place them in a protected storage area.
Prior to reassembly, remove all blanks and check the pipeline for
cleanliness and
signs of damage.
en HTGD 693 000 V0140 A

1667
Blank Page
1668 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0101D -
CHAPTER 2
MAINTENANCE
en HTGD 693 000 V0140 A 1669

2 INITIAL ASSEMBLY
2.1 As-delivered condition
The valves are delivered completely assembled to the site, including the
actuators,
pilot controles, angle transmitters, limit switches and terminal boxes. The
hinged
supports are supplied separately. In special cases the steam strainer is
also shipped
separately. Please ask for the special assembly drawings in this case. The
flange
connecting bolts between the weld-neck flanges, valves, intermediate pipe
spool and
steam strainer are only loosely tightened.
Note
Please make sure that no components are damaged during assembly.
2.2 Welding into the pipeline

If the complete valve is directly welded into the pipeline without
dismantling the weld-
neck flange and the steam strainer, the sealing surfaces between the disc
and the
housing have to be provided with a thick layer of grease before starting the
work.
Note
The welding has to be performed at the lowest possible temperature.
The
sealing surfaces of the valve must not be damaged by welding
spatters.
After welding, the flange connecting bolts 203 and 206 have to be tightened
accord-
ing to Fig. 2 and the following table in order to guarantee perfect
tightness.
DN of valve Bolt size Torque Md (Nm)
250 M 24 295
350 M 24 295
500 M 30 590
700 M 33 800
Fig. 1 Tightening torques for flange joints of intermediate piepe
1670 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0101D -
Low Pressure Butterfly-Type
Valve
Technical
Instructions

200 Intermediate pipe 204 Nut
202 Welding neck flange 205 Gasket*
203 Hexagon head screw 206 Hexagon head screw
* Recommended spare part
Fig. 2 Intermediate pipe
en HTGD 693 000 V0140 A 1671

3 ADJUSTMENT OF THE HINGED SUPPORTS

The valve is adjusted with the cardan joints of the hinged supports which
have left
and right threads. The max. adjustment in height is given in the table in
Fig. 3.
DN of valve Adjustment in height +/- in mm
250 15
350 15
500 20
700 20
Fig. 3 Adjustment of hinged supports
After assembly, the pivoting heads 306 and 307 have to be secured with the
lock
nuts 308 and 309 according to Fig. 4.
1672 HTGD 693 000 V0140 A

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MAC31- HTGD691780V0101D -
Valve
Technical
Instructions

301 Support 308 R-Nut
304 Pipe 309 L-Nut
305 Bolt 310 Washer
306 Pivoting head, L-thread 311 Circlip
307 Pivoting head, R-thread
Fig. 4 Hinged support
en HTGD 693 000 V0140 A

1673
4 MAINTENANCE
If leakages occur during service, the valve seals have to be checked and
exchanged
if necessary.
For this purpose the valve has to be taken out of the pipeline.
Required spare parts are specified with * in the relevant legends and are
available as
per set or per piece.
WARNING
Suspended Load
Wear correct personal protective equipment, hard hat, safety
boots.
Make sure that persons not involved in the procedure are out
of the
danger area.
The lifting device and auxiliary equipment has to be
selected ac-
cording to the weights indicated on the dimensional drawing.
4.1 Valve seals

4.1.1 Dismantling of the actuators
The actuators have to be disconnected hydraulically and electrically from
the supply
system and the coupling for the limit switches and the angle position
transmitter re-
moved from the actuator. The bolts connecting the valve flange and the
actuator
flange have to be loosened.
WARNING
Automatic re-start
Tag-out/Lock-out the pumps for generating the pressure in
the
safety system to prevent unexpected switching-on.
1674 HTGD 693 000 V0140 A

en
MAC31-
HTGD691780V0101D -
Type Valve
Technical
Instructions
Note
The positions of the splined connection have to be marked to
permit re-
assembly in the same position.
The actuators can now be taken off from the valve shaft.
4.1.2 Checks
The valve seals have to be checked for damages and be exchanged if
necessary.
At the same time the movement of the disc in its bearings has to be
checked.
If movement is difficult, the bearings have to be exchanged.
The butterfly-type valve is shown in Fig. 6.
4.1.3 Disassembly of the valve seals

� Loosen the cylindrical pins 1940, tab washers 1950, socket head screws
1960
and headless screws 1920
� Remove the thrust collar 1890 and the retaining ring 1910
� Remove the seals 1660 and 1610
� Clean all parts. Check the seals 1660 and the sealing surface of the disc
Note
The sealing surface of the disc is hard-faced with 40-42 HRC and
can only
be ground with fine grinding cloth.
4.1.4 Re-installation of the valve seals

� Re-install the seals 1660 and 1610
� Re-install the retaining ring 1910 and the thrust collar 1890
� Re-install the cylindrical pins 1940 with tab washers 1950 and socket
head
screws 1960 for positioning the thrust collar 1890
� Re-install the headless screws 1920 which have been inserted from the
back side
into the retaining ring 1910. Tighten these screws according the
following table
DN of valve Torque Md (Nm)
250 7
350 7
500 14
700 24
Fig. 5 Tightening torques for headless screws of valve
en HTGD 693 000 V0140 A

1675
Note
All components have to be adequately greased with MoS2 powder 1
prior
to re-assembly.
No special tools are needed to exchange the seals or dismantle the entire
valve.
4.1.5 Re-assembly of the actuators

Not applicable if the bearings have to be exchanged.
Fig. 6 Butterfly-type valve
1676 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0101D -
Valve
Technical
Instructions
Legend to Fig. 6 Butterfly-type valve

1000 Valve body 3420* Gasket
1180 Close stop 3430 Hexagon head screw
1610* Seal ring 4100* Packring
1660* Sealing 4150 Stud
1890 Thrust collar 4210 Gland bushing
1910 Retaining ring 4220 Gland flange
1920 Grub screw 4250 Belleville spring
1940 Parallel pin 4260 Spring holder
1950 Tab washer 4270* Stopper
1960 Screw 4300 Off-shut-plate
2000 Disc 4310* Lock washer
2100 Spline bush 6010 Cap
2110 Guide bush 6020 Thrust bearing
3000 Drive shaft 6030* Bearing
3110 Bearing ring 6050 Bracket
3120* Bearing 6100 Parallel pin
3130* Bearing seal 6110 Hexagon head screw
3210 Bearing ring 6120 Socket head screw
3220* Bearing 6801 Indicator plug
3230* Bearing seal 6802 Sealing
3300 Spacer 6910 Arrow
3320* Spacer 6920 Tag pressure direction
3340* Spacer 8010 Type plate
3410 Cap
Fig. 6 Butterfly-type valve
12
We recommend one set of spare parts for each stop and control valve
to
have on stock.
en HTGD 693 000 V0140 A

1677
4.2 Bearings
Note
If the bearings have to be exchanged, this work has to be done
before ex-
changing the seals.
4.2.1 Dismantling of the drive shaft

� For this purpose the valve has to be laid down on an even surface with
the drive
shaft 3000 pointing upwards
� Remove the covers 3410 and 6010
� Take off the split ring 6020
� Disconnect the intermediate piece 6050 from the valve and force out the
bushing
6030
� Loosen the plugs 4270 of the of "OPEN/CLOSED" indicator 4300 and the lock
washer 4310. Disconnect the spring holder 4260, Belleville springs 4250,
gland
flange 4220 and gland bushing 4210
Note
The shaft position has to be marked on the disc hubs to facititate
re-
assembly.
� Force out the drive end shaft 3000 in the direction from the non-drive-
end => to
the drive-end
4.2.2 Dismantling of the bearing bushings

� Force out the bushings 3120 and 3220, bearing rings 3110 and 3210 and
take-off
the spacers 3300 and 3320
� Clean and check all parts. Exchange wear parts
� Polish the drive shaft at the baring points with a fine grinding cloth
4.2.3 Re-assembly of the bearing bushings

� Press in the bearing rings 3110 and 3210 and the bushings 3120 and 3220
4.2.4 Re-assembly of the drive shaft

� Insert the drive shaft 3000 in the direction from the drive-end => to the
non-drive-
end and mount the bearing seals 3130 and 3230 and the disc 2000
� Observe the markings
� Install the spacers 3300 and 3320
1678 HTGD 693 000 V0140 A

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MAC31-
HTGD691780V0101D -
Type Valve
Technical
Instructions
� Insert the packing 4100, gland bushing 4210 with gland flange 4220 and
the
Belleville springs 4250 with spring holder 4260
� Bolt the spring holder 4260 to the block
� Mount the "OPEN/CLOSED" indicator 4300 with lock washer 4310 and plug
4270
4.2.5 Re-assembly of the drive-end bearing

� Mount the bushing 6030 to the intermediate piece 6050
� Fasten the intermediate piece 6050 to the valve body
Note
Mount the cover 6010 only loosely on the drive shaft.
� Assemble the split ring 6020 with cover 6010
4.2.6 Re-assembly of the non-drive-end bearing

� Assemble the cover 3410 with gasket 3420
4.2.7 Re-assembly of the actuators

� Observe the markings
4.3 Re-installation of the valve in the pipeline

WARNING
Suspended Load
Wear correct personal protective equipment, hard hat,
safety boots.
Make sure that persons not involved in the procedure are
out of the
danger area.
The lifting device and auxiliary equipment has to be
selected ac-
cording to the weights indicated on the dimensional
drawing.
4.3.1 Screwed joints

The screwed joints 203 and 206 have to be tightened according to Fig. 1.
en HTGD 693 000 V0140 A

1679
Note
Use new seals 205 according to Fig. 2 for the re-assembly.
4.3.2 Re-connection of the valve

The actuators have to be re-connected hydraulically and electrically. The
coupling for
the limit switches and the angular position transmitter have to be mounted
again.
No special tools are needed for the disassembly and assembly of the valve.
5 MAINTENANCE OF THE ACTUATORS

The actuators are lubricated with a long-lasting lubricant in the factory.
After approx.
8'000 working hours the lubricant has to be checked and filled up, if
necessary.
For the disassembly of the actuators, described below, they must not be
taken off
from the valve.
Dismantling of the connections
The hydraulic and electrical connections have to be depressurized and
isolated. The
valve may only be handwarm.
WARNING
Automatic re-start
Tag-out/Lock-out the pumps for generating the pressure in
the
safety system to prevent unexpected switching-on.
5.1 Dismantling of the actuators

The bolts 423 of the spring housing have to be loosened crosswise and
evenly in or-
der to relieve the springs 444 according to Fig. 7.
WARNING
High pretension
The springs 444 are pretensioned.
After loosening the cover 412 and the electrical box, the bolts 418 can be
un-
screwed. The cover 411 with gasket 416 can be removed. The internal side of
the
actuator can now be inspected.
1680 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0101D -
Valve
Technical
Instructions
The rack 403 and the pinion 402 have to be cleaned and checked for wear. The
seals of the servo-parts have to be checked for leaks. If leaks are detected
the seal
shave to be exchanged.
For dismantling the cylinder 406, the hydraulic connections have to be
disconnected
and the nuts 421 and the threaded bolts 407 loosened. The control block 404
can be
removed.
The piston 405 with guide 448 and O-ring seals 451 are accessible. If these
seals
are damaged or worn, they have to be exchanged. For exchanging the O-ring
seal
414, the piston 405 has to be dismantled and the screw 419 loosened. The
flange
428 can now be removed. New O-ring seals have to be mounted.
Note
The adjustment of the stop bolt 445 with lock nut must never be
changed
because the exact closing position of the valve was adjusted in this
way in
the factory.
All components have to be greased with MoS2 Powder 1 prior to re-
assembly.
5.2 Re-assembly of the actuators

The actuators have to be re-assembled in reverse sequence.
No special tools are needed for the disassembly and re-assembly of the
actuators.
en HTGD 693 000 V0140 A

1681
Fig. 7 Actuator
1682 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0101D -
Valve
Technical
Instructions
Legend to Fig. 7 Actuator

401 Body 422 Stay bolt
402 Pinion 423 Hexagon head bolt
403 Shaft 424 Spring body
404 External head 425 Disc
405 Piston 426 Flange
406 Cylinder 427 Bushing
407 Stay bolt 428 Flange
408 Bushing 429 Shaft
409 Bushing 430 Position stop bolt
410 Spring cover 440 Block nut
411 Cover 441 Hexagon head bolt
412 Cover 442 Rack
413 Bushing 443 Bushing
414* O-Ring 444 Cup springs
415* O-Ring 445 Position stop bolt
416* Cover gasket 446 Block nut
417* O-Ring 447* O-Ring
418 Hexagon head bolt 448* Piston guidance
419 Socket head screw 449 Disc
420 Hexagon head bolt 450* O-Ring
421 Nut 451* O-Ring
Fig. 7 Actuator
12
We recommend one set of spare parts for each actuator of the stop
and
control valve to have on stock.
en HTGD 693 000 V0140 A

1683
5.3 Pilot controls

5.3.1 Pilot control of control valve
The pilot control is shown in Fig. 8.
Fig. 8 Pilot control of control valve
1684 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0101D
-
Type Valve
Technical
Instructions
Legend to Fig. 8 Pilot control of control valve

501 Body 522 Check valve
502 Body cover 523 Threaded stem
503 Cover 524 Threaded stem
504 Valve body 525 Threaded stem
505 Valve plate 526 Screw plug
506* O-ring 527 Eyebolt
507* O-ring 528 Socket head screw
508* Proportional control valve 529 Socket head screw
509 Protection 530 Socket head screw
510 Orifice 531 Socket head screw
511 Orifice 532 Spring washer
519* O-ring 535 Compression spring
520* O-ring 580* Power amplifier
521* O-ring
Fig. 8 Pilot control of control valve
en HTGD 693 000 V0140 A

1685
5.3.2 Pilot control of stop valve

The pilot control is shown in Fig. 9
Fig. 9 Pilot control of stop valve
1686 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0101D
-
Type Valve
Technical
Instructions
Legend to Fig. 9 Pilot control of stop valve

601 Body 622 Check valve
602 Body cover 625 Threaded stem
603 Cover 626 Screw plug
604 Valve body 627 Eyebolt
605 Valve plate 628 Socket head screw
608* Solenoid valve 631 Socket head screw
609 Protection 632 Spring washer
620* O-ring 635 Compression spring
621* O-ring
Fig. 9 Pilot control of stop valve
en HTGD 693 000 V0140 A

1687
5.3.3 Terminal box

The terminal box is shown in Fig. 10.
Fig. 10 Terminal box
1688 HTGD 693 000 V0140 A en

MAC31- HTGD691780V0101D -
Valve
Technical
Instructions
Legend to Fig. 10 Terminal box

701 Base plate 713 Washer
702 Cover 714 Type plate
703 Disc 715 Direction arrow
704 Coupling 716 Plate "OPEN"
705 Trip cam 717 Plate "SHUT"
706 Pipe 718 Rivet
707 Socket head screw 720* Angle transmitter
708 Socket head screw 721 Plug
709 Hexagon head bolt 722 Clamp
710 Grub screw 725* Proximity sensor
711 Grub screw 726 Nut
712 Flat head screw 727 Plug
Fig. 10 Terminal box
en HTGD 693 000 V0140 A 1689

6 CLEANING OF THE STEAM STRAINER

Loosen screw plugs 127, socket head screws 126 of the strainer attachment,
hexa-
gon head bolts 110 and then remove cover 104 according to Fig. 11.
Fig. 11 Steam strainer
1690 HTGD 693 000 V0140 A

en
MAC31- HTGD691780V0101D
-
Type Valve
Technical
Instructions
Legend to Fig. 11 Steam strainer

100 Body complete 120 Trap complete
104 Cover 121 Trap body
108 Screw plug 122 Trap body
109 Eyebolt 123 Fine strainer
110 Hexagon head bolt 124 Commissioning strainer
111 Tab washer 126 Socket head screw
112* Gasket 127 Screw plug
Fig. 11 Steam strainer
The strainer can be removed with the lifting device.

After cleaning the strainer and exchanging the seal 112, the strainer can be
re-
mounted in reverse sequence.
Tighten the bolts 110 according to Fig. 12.
DN of valve Bolt size Torque Md (Nm)
250 M 24 295
350 M 24 295
500 M 30 590
700 M 33 800
Fig. 12 Tightening torques for flange joints of steam strainer
7 GENERAL MAINTENANCE OF THE VALVE

The valve is almost maintenance-free. The hydraulic connections and the
actuators
have to be checked periodically for leaks. If such leaks are detected, the
screwed
joints have to be tightened or the seals be exchanged.
en HTGD 693 000 V0140 A

1691
Blank Page
HTGD691780V0101D
1692 HTGD 693 000 V0140 A en

MAC80 - HTGD690182V9000 -
Constant Pressure Valve
MAC80 - HTGD690182V9000 -
en HTGD 693 000 V0140 A 1693

Revision History
total :
- - (12)
1694 HTGD 693 000 V0140 A en

MAC80 - HTGD690182V9000 -
Contents
1
PURPOSE............................................................................
............................................................1697
2
CONSTRUCTION ......................................................................
......................................................1699
3 PRINCIPLE OF
OPERATION .........................................................................
.................................1699
4 CAUSES OF MALFUNCTIONS AND CORRECTIVE
ACTIONS ....................................................1699
5 DISMANTLING AND RE-
ASSEMBLY ..........................................................................
...................1700
5.1
Dismantling .......................................................................
................................... 1700
5.2 Re-
assembly ..........................................................................
.............................. 1704
en HTGD 693 000 V0140 A

1695
WP4110 & WP4140
Figures
Fig. 1 General
view...............................................................................
................................... 1698
Fig. 2 Sectional
view...............................................................................
................................. 1703
Synopsis of test certificates
1696 HTGD 693 000 V0140 A

en
MAC80 - HTGD690182V9000
-
Constant Pressure
Valve
1 PURPOSE
The constant pressure valve is a proportional controller which limits the
pressure of a
hydraulic medium admitted to its input side according to adjustment and valve
char-
acteristic.
en HTGD 693 000 V0140 A

1697

2 Valve housing (a) Hydraulic system
3 Spring cover (b) Drain
4 Valve piston (c) Pilot control system
5 Piston rod (d) Leakage
12 Compression spring (e) Gage connection
19 Setscrew (y) Piston surface
Fig. 1 General view
1698 HTGD 693 000 V0140 A en

MAC80 - HTGD690182V9000
-
Constant Pressure
Valve
2 CONSTRUCTION
The pressure of the hydraulic system (a) is also transmitted to the valve
piston 4 via
connection (c) according to Fig. 1. The system pressure and the counteracting
force
of the compression spring 12 determine the pressure in the hydraulic system
(a).
The desired value within the control range can be adjusted by the setscrew 19.
3 PRINCIPLE OF OPERATION
The pressure of the hydraulic system (a) is admitted via the pilot control
connection
(c) to the surfaces (y) of the valve piston according to Fig. 1, pushing the
piston 4
against the compression spring 12. With sufficiently high pressure, the valve
piston is
lifted so far that the drain (b) is cleared. The pressure in system (a)
decreases.
The constant pressure valve can be employed for the control range indicated on
its
rating plate.
4 CAUSES OF MALFUNCTIONS AND CORRECTIVE ACTIONS

The following points describe malfunctions or oscillations in the hydraulic
system and
how to correct them according to Fig. 1 and Fig.2:
� System line at connection (c) not vented or too small.
Vent the line, or increase its cross-section and make sure they are laid
with a
steady rise.
� System pressure deviates from the setpoint value.
Remove cap nut 27, unscrew nut 30, and use setscrew 19 to set precisely the
setpoint pressure.
� Constant pressure valve does not respond to pressure changes.
Remove valve piston 4, clean it and eleminate any friction marks.
en HTGD 693 000 V0140 A

1699
5 DISMANTLING AND RE-ASSEMBLY

Under normal circumstances the constant pressure valve does not require
mainte-
nance.
WARNING
Pressure hazard
Do not lean or bend over pressurised equipment.
Dismantling is only permitted after the system has been
pressure-
relieved.
Make sure that persons not involved in the operation are
outside the
danger area.
Note
During dismantling, care must betaken to make sure that all parts
coming
into contact with pressure medium are absolutely clean.
5.1 Dismantling
Starting point
Remove the connecting lines and bolted joints from the tank and pressure
line and
lift-off the constant pressure valve.
Note
Pay attention to escaping pressure medium. Make available an oil
pan.
� Remove the cap nut 27 according to Fig. 2 by loosening the hex. nut 30 and
set-
screw 19.
Note
Prior to relieving the compression spring record the operating
position of
the setscrew 19 to permit the same setting after re-assembly.
� Relieve the compression spring 12 as far as possible.
� Unscrew the hex. head bolts 24.
� Loosen uniformly the opposite arranged hex. nuts 29 from the studs 20
until the
compression spring 12 is completely relieved.
1700 HTGD 693 000 V0140 A

en
MAC80 - HTGD690182V9000
-
Constant Pressure
Valve
Note
Important!
Ensure that the studs 20 do not rotate.
� Remove the hex. nuts 29 and the spring cover 3 from the valve housing
2.Remove the gasket 39.
� Dismantle the compression spring 12 with the spring plates 10.
� Dismantle the circlip 37 and remove the spring support plate 8 from the
valve pis-
ton 4.
� Dismantle the socket head screws 25, tension spring washer 36 and retaining
disk 7.
� Pull the valve piston 4 with piston ring 6 out of the valve housing.
en HTGD 693 000 V0140 A

1701
Legend to Fig. 2 Sectional view

2 Valve housing 22 Screw plug
3 Spring cover 24 Hex. head bolt
4 Valve piston 25 Socket head screw
5 Piston rod 27 Cap nut
6 Piston ring 29 Hex. nut
7 Retaining disk 30 Hex. nut
8 Spring support plate 33 Rollpin
10 Spring plate 36 Tension spring washer
12 Compression spring 37 Circlip
19 Setscrew 38 Gasket
20 Treaded stud 39 Gasket
1702 HTGD 693 000 V0140 A en

MAC80 - HTGD690182V9000 -
Fig. 2 Sectional view
en HTGD 693 000 V0140 A 1703

5.2 Re-assembly
Re-assemble in reverse order.
Note
Clean thouroughly all parts coming into contact with pressure
medium
bevore re-assembling.
Adjust the setscrew 19 of the compression spring according to the
record
measurement from the dismantling.
Tighten the hex. head bolts 24 and the bolted joint of the pres- Document
sure line according to the values given in the document. HTGD 630
147
Re-connect all connecting lines leak-tight.
HTGD690182V9000
1704 HTGD 693 000 V0140 A

en
MAD21 - HTGD690143V9014 -
Combined Two Collar Thrust
and Journal Bearing
with jacking oil connection
MAD21 - HTGD690143V9014 -
and Journal Bearing
en HTGD 693 000 V0140 A 1705

Revision History
total :
- - (16)
1706 HTGD 693 000 V0140 A en

MAD21 - HTGD690143V9014 -
and Journal Bearing
Contents
1 GENERAL
DESCRIPTION .......................................................................
.......................................1709
1.1 Construction and principle of

operation ............................................................... 1710
1.2 Lubricating oil
supply ............................................................................
............... 1711
1.3 Temperature
monitoring.........................................................................
.............. 1714
2
MAINTENANCE .......................................................................
........................................................1716
3
DISMANTLING........................................................................
.........................................................1717
3.1 Dismantling steps and

records............................................................................
. 1717
3.2 Checks and
measurements ......................................................................
........... 1718
4 RE-
ASSEMBLY...........................................................................
.....................................................1719
4.1 Re-assembly
preparations ......................................................................
............. 1719
4.2 Check measurements during re-
assembly .......................................................... 1719
en HTGD 693 000 V0140 A

1707
WP4110 & WP4140
Figures
Fig. 1 General
view...............................................................................
................................... 1709
Fig. 2 Journal bearing and oil
inlet..............................................................................
............. 1710
Fig. 3 Fixation of the
bearing ...........................................................................
........................ 1711
Fig. 4 Axial
shims .............................................................................
....................................... 1712
Fig. 5 Adjusting plate oil inlet
side ..............................................................................
............. 1712
Fig. 6 Arrangement of thrust
pads ..............................................................................
............. 1713
Fig. 7 Thermocouple at a thrust
pad................................................................................
........ 1714
Fig. 8 Arrangement of spring
ring ..............................................................................
.............. 1715
1708 HTGD 693 000 V0140 A

en
MAD21 - HTGD690143V9014 -
Combined Two Collar
Thrust
and Journal
Bearing
with jacking oil
connection
The combined thrust and journal bearing, shown in Fig. 1, works on the
hydrody-
namic principle, thereby assuring freedom form contact, low friction, almost
no wear
and long life of the bearing surfaces.

1 Bearing body, complete 13 Cylindrical pin
5 Bearing shell, complete 31 Orifice
6 Set of thrust pads 35 Double thermocouple
7 Set of thrust pads 36 HP Plug
8 Two-piece spring ring 37 Check valve
9 Ring 65 Cylindrical pin
11 Set of shims 72 Jacking oil connection
Fig. 1 General view
en HTGD 693 000 V0140 A

1709
1.1 Construction and principle of operation

The combined thrust and journal bearing transmits the axial thrust forces,
along with
the weight of the rotor, to the bearing pedestal. Its parts are the bearing
body with
shim plates, the thrust bearing pads with spring rings and the journal
bearing shell.
The journal bearing is located between the two separate thrust bearing
halves which
absorb the thrust from both directions. The horizontally split bearing body
is fixed by
means of bolts and locating pins and can be adjusted axially and radially by
means
of shim plates.

16 Set of shims 57 Hexagon head bolt
17 Set of shims 58 Taper pin
50 Adjusting plate 59 Lock washer
51 Bearing body, upper part 62 Bearing shell, lower
part
52 Bearing body, lower part 63 Bearing shell, upper
part
53 Adjusting plate 71 Lube oil inlet
55 Adjusting plate
Fig. 2 Journal bearing and oil inlet
To ensure uniform distribution of the axial forces to the individual

segments, the
thrust bearing pads are backed by spring rings. In the case of surge thrusts
the
spring rings have a damping effect. The axial clearance of the bearing is
adjusted by
means of intermediate rings.
1710 HTGD 693 000 V0140 A

en
MAD21 -
HTGD690143V9014 -
Combined Two
Collar Thrust
and
Journal Bearing
with jacking oil
connection
1.2 Lubricating oil supply

The lubricating oil flows to the lateral oil inlet at the bearing via a bore
in the bearing
pedestal and a channel in the parting plane. From the oil inlet the oil
passes in an
annular channel between bearing body and journal bearing shell and from there
to
the inlet wedge of the journal bearing and the thrust bearing halves.

12 Locking plate 59 Lock washer
28 Countersunk screw 61 Rollpin
54 Adjusting plate 64 Socket head screw
57 Hexagon head bolt 66 Cylindrical pin
58 Taper pin
Fig. 3 Fixation of the bearing
en HTGD 693 000 V0140 A

1711

14 Shim plate 27 Pan-head screw
15 Set of shims
Fig. 4 Axial shims

55 Adjusting plate 61 Rollpin
Fig. 5 Adjusting plate oil inlet side
Discharge orifices and shaft sealing rings keep the internal chambers of
each thrust
bearing permanently filled with lubricating oil to assure lubrication and
cooling of all
thrust bearing pads.
1712 HTGD 693 000 V0140 A

en
MAD21 -
HTGD690143V9014 -
Combined Two Collar
Thrust
and Journal
Bearing
with jacking oil
connection

8 Two-piece spring ring 27 Pan-head screw
9 Two-piece ring 31 Orifice
26 Rollpin 56 Seal profile
Fig. 6 Arrangement of thrust pads
Jacking oil lubrication is provided for higher loaded journal bearings.

Lifting the rotor
with jacking oil prevents metallic contact of bearing metal and bearing
journal during
turning gear operation, startup and shutdown. The friction coefficient in the
journal
bearing and consequently the torque to be generated by the turning gear are
thus
reduced considerably.
en HTGD 693 000 V0140 A

1713
1.3 Temperature monitoring

The bearing metal temperature is a suitable criterion for monitoring the
condition of
the bearing. Thermocouples measure the bearing metal temperature in the
lower
bearing shell and in one segment in each of the thrust bearing rings.
An alarm and a turbine trip are initiated by excessive temperatures.

34 Double thermocouple
Fig. 7 Thermocouple at a thrust pad
1714 HTGD 693 000 V0140 A

en
MAD21 - HTGD690143V9014 -
and Journal Bearing

8 Two-piece spring ring
Fig. 8 Arrangement of spring ring
en HTGD 693 000 V0140 A 1715

2 MAINTENANCE
Absolute cleanliness is required during dismantling and assembly of all
parts of the
bearing and bearing pedestal coming into contact with lube oil. These
activities re-
quire personnel with comprehensive technical knowledge.
Caution
Do not let silicone compounds get into the turbine bearings or oil system.
Silicone
can cause contamination.
1716 HTGD 693 000 V0140 A

en
MAD21 -
HTGD690143V9014 -
Combined Two
Collar Thrust
and
Journal Bearing
with jacking
oil connection
3 DISMANTLING
3.1 Dismantling steps and records

Loosen and lift-off the bearing pedestals cover.
Remove the thermocouples.
Measure and record the clearances of the oil shields according Test
certificate
499 343
HTGD
667 267
Measure and record the position of the turbine rotor with re- Test
certificate
gards to the bearing pedestal according to the test certificate. HTGD
667 274
Remove the oil shields.

Loosen the bolted joint of bearing body upper and lower part and lift off the
bearing
body.
Lift carefully the spring ring upper part with the thrust pads.
Turn out the spring ring lower part with the thrust pads and lift it
carefully.
Loosen the bolted joint of the bearing shell upper and lower part and lift-
off the bear-
ing shell upper part.
Remove the cable clamps and disconnect the thermocouples from the terminal
box.
Lift the turbine rotor with the rotor raising device by 0.2.to 0.3 mm.
Note
Supervise the lifting with a dial gauge
Screw two eyebolts into one side of the bearing body lower part and using
hoisting
equipment carefully rotate the complete lower bearing and shell parts around
the ro-
tor shaft until the thermocouples can be removed.
Remove the thermocouples for the thrust and radial lower bearings from the
lower
bearing body. Mark them with the KKS designations.
Rotate the bearing body until it is on top of the shaft and the split line is
horizontal,
attatch lifting eyes and carefully lift off with hoisting equipment and set
down on suit-
able wooden blocks.
Lift of the journal bearing shell.
en HTGD 693 000 V0140 A
1717
WARNING
Suspended Load
danger
area.
3.2 Checks and measurements

� Check the bearing metal for cracks and lack of fusion.
� Equalize carefully scratches in the bearing metal. Replace the bearing
shell, if
necessary.
� Check the contact surfaces of the bearing shell lower part.
� Check the adjusting plates for damages.
� Check the surfaces of the collars and thrust pads for roughness and
unevenness.
� Check the thrust pads for uniform contact.
Check and record all clearances according to the test certifi- Test
certificate
cate. HTGD
667 273
The following measurements relate to this Test certificate.

The radial clearance "V" can be measured using the following methods:
Attach dial gauge at the highest point, between the bolted bearing shell and
shaft.
Lift carefully the shaft with with the auxiliary bearing or rotor raising
device until the
journal bearing rests loosely on the shaft. Read off the difference as
clearance "V" at
the dial gauge.
� Measure vertical the dismantled, bolted bearing shell and the shaft
journal.
� Measure the lateral clearances "F1" and "F2". The lateral adjusting plates
may not
jam in the bearing pedestal bore.
� Measure the clearance E (resp. the clamp E for a combined bearing located
as a
HP front bearing) between the upper adjusting plate and the bearing
pedestal
cover in accordance with the test certificate (for example with lead
imprint).
� Measure the axial clearances "C" and "D". In case of clearance "D", make
sure
that the bearing body can still be turned out easily.
1718 HTGD 693 000 V0140 A

en
MAD21 -
HTGD690143V9014 -
Combined Two Collar
Thrust
and Journal
Bearing
with jacking oil
connection
4 RE-ASSEMBLY
Re-assemble in reverse order as dismantling.
Note
Important :
Absolute cleanliness is required during re-assembly.
4.1 Re-assembly preparations

The following points have to be observed, specially if a new bearing or new
bearing
parts are installed:
� Make sure during reassembly that the locking pins of the bearing shell and
bear-
ing body are installed in the upper adjusting plates.
� The spring rings must be absolutely parallel to the shaft collar. The
bearing body
upper half and the two sets of thrust pads have to be dismantled to permit
the
parallelism check.
4.2 Check measurements during re-assembly

Adjust and record the position of the turbine rotor with regards Test
certificate
to the bearing pedestal according to the test certificate. HTGD 667
274
certificate
to the turbine shaft alignment according to the test certificate. 1BSE 501
730
Adjust and record the position of the oil shields with regards to Test
certificate
the rotor according to the test certificate. HTGD 499
343
HTGD 667
267
Check all clearances according to the test certificate and re- Test
certificate
adjust if necessary. Make sure when adjusting the thrust bear- HTGD 667
273
ing clearance that the values "S" measured at the circumfer-
ence in the bearing body do not exceed the deviation toler-
ance.
Note
The proper function of the jacking oil system has to be checked after each
over-
haul.
The rotor must lift at least 0.02 mm.
en HTGD 693 000 V0140 A

1719
Blank Page
HTGD690143V9014
1720 HTGD 693 000 V0140 A en

MAD51 - HTGD690524V9026 - Pocket-Type Journal Bearing
MAD51 - HTGD690524V9026 -
Pocket-Type Journal Bearing
en HTGD 693 000 V0140 A 1721

Revision History
total :
- - (14)
1722 HTGD 693 000 V0140 A en

MAD51 - HTGD690524V9026 -
Pocket-Type Journal Bearing
Contents
1 GENERAL
DESCRIPTION .......................................................................
.......................................1725
1.1
Construction.......................................................................
.................................. 1726
1.2 Lubricating oil
supply ............................................................................
............... 1729
1.3 Jacking oil
supply.............................................................................
.................... 1730
1.4 Temperature
monitoring.........................................................................
.............. 1731
2
MAINTENANCE .......................................................................
........................................................1731
3
DISMANTLING........................................................................
.........................................................1732
3.1 Dismantling steps and

records............................................................................
. 1732
3.2 Checks and
measurements ......................................................................
........... 1732
4 RE-
ASSEMBLY...........................................................................
.....................................................1734
4.1 Re-assembly
preparations ......................................................................
............. 1734
4.2 Check measurements during re-
assembly .......................................................... 1734
en HTGD 693 000 V0140 A

1723
WP4110 & WP4140
Figures
Fig. 1 General
view...............................................................................
................................... 1725
Fig. 2 Bearing shells with oil
inlet .............................................................................
............... 1726
Fig. 3 Arrangement of
thermocouple ......................................................................
................. 1727
Fig. 4 Bolted joint in the parting
plane .............................................................................
........ 1728
Fig. 5 Fixation of the bearing
shells.............................................................................
............ 1729
Fig. 6 Arrangement of drain
bores..............................................................................
............. 1729
Fig. 7 View onto parting
plane .............................................................................
.................... 1730
Fig. 8 Jacking oil
connection ........................................................................
........................... 1731
1724 HTGD 693 000 V0140 A

en
with jacking oil
connection
The pocket-type journal bearing, shown in both Fig. 1 and Fig. 2, works on the
hy-
drodynamic principle to make sure of freedom from contact, low friction,
minimum
wear and maximum life of all bearing surfaces.
The design uses the minimum space necessary.
Fig 3
1
Fig 3
72
CNDB0109_

1 Bearing shell, lower part 72 Jacking oil connection
2 Bearing shell, upper part
Fig. 1 General view
en HTGD 693 000 V0140 A

1725
1.1 Construction
The fully enclosed journal bearing has two bearing shell halves, which have
a layer
of white metal on the inner surface, the shells are aligned with cylindrical
pins and
connected together with socket head screws.
49 20 10
31 67
12
14 14
31
31
15
71
15
11
11
23 10
31 27 13
CNDB0110_

10 Set of shims 20 Cylindrical pin
11 Set of shims 23 Jacking oil plug
12 Adjusting plate 27 Check valve
13 Adjusting plate 31 Socket head screw
14 Adjusting plate 49 Bushing
15 Adjusting plate 67 Cylindrical pin
71 Lube oil inlet
Fig. 2 Bearing shells with oil inlet
The bearing is installed in a bearing pedestal. The bearing is clamped with

the ad-
justing plate unless the bearing is located in an axial LP-exhaust. In this
case the
bearing is assembled with clearance. The shims below the adjusting plate
permit the
adjustment of the bearing.
The bearing is prevented from turning by a cylindrical pin which engages in
the ped-
estal upper half.
1726 HTGD 693 000 V0140 A

en

73 Bore for thermocouple
Fig. 3 Arrangement of thermocouple
en HTGD 693 000 V0140 A 1727


22 Cylindrical pin 71 Lube oil inlet
Fig. 4 Bolted joint in the parting plane
1728 HTGD 693 000 V0140 A en

MAD51 - HTGD690524V9026 - Pocket-Type Journal
Bearing
with jacking oil
connection
35
22
CNDB0113_
22 Cylindrical pin 35 Hexagon socket screw
Fig. 5 Fixation of the bearing shells
1.2 Lubricating oil supply

The lubricating oil flows to the lateral oil inlet at the bearing via a bore
in the bearing
pedestal and a channel in the parting plane of the bearing pedestal. From
there to
the inlet wedge of the journal bearing shell.
On both facesides the oil flows out of the bearing over the whole shaft
circumference
via bores.
Fig. 6 Arrangement of drain bores
en HTGD 693 000 V0140 A

1729
1.3 Jacking oil supply

Jacking oil lubrication is provided for higher loaded journal bearings.
Lifting the rotor
with jacking oil prevents metallic contact between the bearing metal and
bearing
journal during turning gear operation, startup and shutdown.
Fig 8
Fig 8
71 CNDB0112_
71 Lube oil inlet
Fig. 7 View onto parting plane
The friction coefficient in the journal bearing and consequently the torque
to be gen-
erated by the turning gear are considerably reduced.
1730 HTGD 693 000 V0140 A

en
MAD51 - HTGD690524V9026 - Pocket-Type Journal
Bearing
with jacking oil
connection
23
27
CNDB0108_
A1367

23 Jacking oil plug 27 Check valve
Fig. 8 Jacking oil connection
1.4 Temperature monitoring

The bearing metal temperature is a suitable criterion for monitoring the
condition of
the bearing. Thermocouples measure the bearing metal temperature in the lower
bearing shell using two double thermocouples. An alarm and a turbine trip are
initi-
ated by excessive temperatures.
2 MAINTENANCE
Absolute cleanliness is required during dismantling and assembly of all
bearing parts
and bearing pedestal parts that come into contact with lube oil. These
maintenance
activities require the personnel to have a comprehensive technical knowledge.
Caution
Do not let silicone compounds get into the turbine bearings or oil system.
Silicone
en HTGD 693 000 V0140 A

1731
3 DISMANTLING
3.1 Dismantling steps and records

Loosen and lift-off the bearing pedestals cover.
Remove the thermocouples.
Measure and record the clearances of the oil shields according Test
certificate
499 343
HTGD
667 267
Measure and record the position of the turbine rotor with re- Test
certificate
gards to the bearing pedestal according to the test certificate. HTGD
667 274
Remove the oil shields and loosen the bolted joint of bearing shell upper
and lower
parts.
Screw two eyebolts into the bearing shell upper part and lift-off the
bearing shell.
Lift the turbine rotor with the auxiliary bearing or the rotor raising
device by 0.2 to 0.3
mm.
Note
Monitor the lifting with a dial gauge
Turn out and lift-off the bearing shell lower part.
WARNING
Suspended Load
danger
area.
3.2 Checks and measurements

� Check the bearing metal for cracks and lack of fusion.
� Equalize carefully scratches in the bearing metal. Replace bearing shell,
if neces-
sary.
1732 HTGD 693 000 V0140 A

en
with jacking oil
connection
� Check the contact surfaces of the bearing shell lower part.

� Check the adjusting plates for damage.
Check and record all clearances according to the test certifi- Test
certificate
cate. HTGD 667
263
HTGD 667
459
The radial clearance "V" can be measured using the following methods:
Attach the dial gauge at the highest point, between the bolted bearing shell
and the
shaft. Lift carefully the shaft with the auxiliary bearing or the rotor
raising device until
the journal bearing rests loosely on the shaft. Read off the difference as
clearance
"V" at the dial gauge.
� Measure vertical the dismantled, bolted bearing shell and the shaft journal.
� Measure the lateral clearances "F1" and "F2". Also clearances "F3" and "F4"
if an
insert ring is installed. The lateral adjusting plates must not jam in the
bearing
pedestal bore.
� Measure the clearance "E" between the upper adjusting plate and the bearing
pedestal cover, for example with lead imprint.
en HTGD 693 000 V0140 A

1733
4 RE-ASSEMBLY
Re-assemble in reverse order as dismantling.
Note
Important :
Absolute cleanliness is required during re-assembly.
4.1 Re-assembly preparations

The following point has to be observed, especially if a new bearing or new
bearing
parts are being installed:
� Make sure during re-assembly that the locking pin and the bushing is
installed in
the upper bearing shell adjusting plate.
4.2 Check measurements during re-assembly

certificate
to the bearing pedestal according to the test certificate. HTGD 667
274
certificate
to the turbine shaft alignment according to the test certificate. 1BSE 501
730
Adjust and record the position of the oil shields with regards to Test
certificate
the rotor according to the test certificate. HTGD 499
343
HTGD 667
267
Check all clearances according to the test certificate and re- Test
certificate
adjust if necessary. HTGD 667
263
HTGD 667
459
Note
The correct operation of the jacking oil system has to be checked after each
over-
haul.
The rotor lift must be at least 0.02 mm.
HTGD690524V9026
1734 HTGD 693 000 V0140 A

en
MAD51 - HTGD693038V9009 -
Disassembly and Re-assembly of the LP Internal Bearing
MAD51 - HTGD693038V9009 -
the LP Internal Bearing
en HTGD 693 000 V0140 A 1735

Revision History
total :
- 04-17-05, Revised to latest build -
- - (32)
1736 HTGD 693 000 V0140 A en

MAD51 -
HTGD693038V9009 -
the LP Internal Bearing
Contents
1 DISASSEMBLY OF THE LP INTERNAL

BEARING ........................................................................174
0
1.1
Preparations.......................................................................
.................................. 1740
1.2 Opening the outer
casing.............................................................................
........ 1741
1.2.1 Removing the Rupture diaphragm
support ............................................. 1741
1.3 Dismantling the enclosure and the LP shaft
seal................................................. 1741
1.3.1 Loosening the parting flange bolts of the
enclosure................................ 1741
1.3.2 Installing the Disassembly
Device........................................................... 1743
1.3.3 Dismantling the instruments in the bearing
casing.................................. 1744
1.4 Dismantling the journal
bearing ...........................................................................
1745
1.4.1 Dismantling the bearing
bracket.............................................................. 1746
1.4.2 Dismantling the journal bearing upper
part ............................................. 1747
1.4.3 Dismantling the journal bearing lower
part .............................................. 1749
2 RE-ASSEMBLY OF THE LP INTERNAL
BEARING........................................................................1752
2.1 Starting
point..............................................................................
.......................... 1752
2.1.1
Turbine ...........................................................................
......................... 1752
2.2 Re-installing the journal
bearing ..........................................................................
1752
2.2.1 Installing the journal bearing lower
part................................................... 1752
2.2.2 Installing the journal bearing upper
part .................................................. 1754
2.2.3 Check measurements after installing the
bearing ................................... 1756
2.2.4 Installing the bearing
bracket .................................................................. 1757
2.2.5 Checking the Rotor
jacking ..................................................................... 1760
instruments........................................................................
. 1760
enclosure..........................................................................
.. 1762
2.3 Closing the outer
casing ............................................................................
.......... 1764
2.3.1 Installing the rupture diaphragm
support................................................. 1765
2.4 Final
remarks ...........................................................................
............................ 1765
en HTGD 693 000 V0140 A

1737
WP4110 & WP4140
Figures
Fig. 1-1 Opening the outer

casing ............................................................................
............... 1741
Fig. 1-2 Dismantling the enclosure and the LP shaft
seal ....................................................... 1743
Fig. 1-3 Installing the Disassembly device to the
enclosure.................................................... 1744
instruments .......................................................................
................ 1745
Fig. 1-5 Dismantling the bearing
bracket............................................................................
..... 1747
Fig. 1-6 Dismantling the journal bearing upper
part ................................................................ 1749
device.............................................................................
... 1750
Fig. 2-1 Re-Installing the journal bearing lower
part................................................................ 1754
Fig. 2-2 Re-installing the journal bearing upper
part ............................................................... 1756
Fig. 2-3 Installing the bearing
bracket ...........................................................................
.......... 1759
instruments........................................................................
.................... 1761
Fig. 2-5 Removing the Disassembly device from the
enclosure.............................................. 1762
enclosure..........................................................................
..................... 1764
Fig. 2-7 Closing the outer
casing.............................................................................
................ 1765
Synopsis of the test certificates
Bolt tensioning devices, stretching method
Hydraulic stretching of elongation bolts
Bolt tensioning devices, torque screw driver
1738 HTGD 693 000 V0140 A

en
MAD51 - HTGD693038V9009 -
CHAPTER 1
DISASSEMBLY OF THE LP INTERNAL BEARING
en HTGD 693 000 V0140 A 1739

1 DISASSEMBLY OF THE LP INTERNAL BEARING

12
MAC10
Note
Preliminary remarks.
Inspect all parts removed from the turbine for damage and store them at
a dry safe
place until re-assembly.
Clean the tools after use, check them for completeness and store them in
the tool
cabinet.
Caution
Do not let silicone compounds get into the turbine bearings or oil
system. Silicone
1.1 Preparations
Note
Mark all electric connections for the thermocouples and instruments at
the LP tur-
bine Bearing for re-assembly and disconnect them.
WARNING
Automatic re-start
Tag-out/Lock-out the pumps for generating the pressure in the system
to pre-
vent unexpected switching-on.
1740 HTGD 693 000 V0140 A

en
MAD51 - HTGD693038V9009
-
Disassembly and Re-assembly of the LP Internal
Bearing
1.2 Opening the outer casing

1.2.1 Removing the Rupture diaphragm support
To get access to the LP bearing in the exhaust casing, loosen the hexagon
head
bolts 128 at the outer casing upper half refer to Fig. 1-1 and remove the
rupture dia-
phragm support 126 with the rupture diaphragm 129.
BGAX0301_
A2468

126 Rupture diaphragm support 128 Hexagon head bolt
127 Seal 129 Rupture diaphragm
assembly
Fig. 1-1 Opening the outer casing
1.3 Dismantling the enclosure and the LP shaft seal

1.3.1 Loosening the parting flange bolts of the enclosure
Lower the hoisting equipment through the opening for the rupture diagram
and at-
tach it to the cover 191, refer to Fig. 1-2.
Loosen the hexagon head screws 190 and remove the cover 191.
en HTGD 693 000 V0140 A

1741
WARNING
Suspended Load
danger
area.
Loosen the hexagon head bolts 117 on both sides of the enclosure and remove
the
covers 116, refer to Fig. 1-2.
Loosen and remove the socket head screws 416 with the washers 417 at the
shaft
seal upper part 402 through the openings in the enclosure.
Loosen and remove also the socket head screws 121 in the parting plane in
the en-
closure interior through these openings.
Measure and record the radial clearance of the oil shield upper Test
certificate
part 169, refer to the test certificate. HTGD
499 343
HTGD
667 267
Loosen and remove all socket head screws 121 in the parting plane on the
outside of
the enclosure.
Lift the enclosure 102 by 3 to 5 mm using four jack screws 902 .
Attach the hoisting equipment to the enclosure, refer to Fig. 1-2.
Note
Lift off the enclosure exactly vertically in horizontal position. Make sure
that all bolts
in the enclosure interior have been loosened and removed.
Lift the enclosure 102 with the hoisting equipment.

Put support blocks between the upper and lower enclosure parts to let safe
installa-
tion of the Disassembly device parts.
1742 HTGD 693 000 V0140 A

en
MAD51 -
HTGD693038V9009 -
Disassembly and Re-assembly of the LP
Internal Bearing
902 121
905
902
905
815
102
416
417
117
116
121
190
169
191
402
BFAB0403_

102 Bearing casing enclosure upper 402 Shaft seal upper
part
116 Cover 416 Socket head
screw
169 Oil shield upper part 902 Jack screw
190 Hexagon head screw 905 Taper pin (not
inserted)
191 Cover
Fig. 1-2 Dismantling the enclosure and the LP shaft seal
1.3.2 Installing the Disassembly Device

Install the Disassembly device parts refer to Fig. 1-3.
Attach the hoisting equipment to the lifting strap 913 .
en HTGD 693 000 V0140 A

1743
Lift the upper enclosure and fit the support bars 914 refer to Fig. 1-3.
102
913
912
914
915
916
917
911
915
910
BGAB0105_

102 Enclosure upper Half 914 Support Bar
910 Hinge 915 Socket Screw
911 Support Upper Half 916 Washer
912 Support Upper Half 917 Nut
913 Lifting Strap
Fig. 1-3 Installing the Disassembly device to the enclosure.
1.3.3 Dismantling the instruments in the bearing casing
Note
Mark all electric connections for the thermocouples and instruments at the
turbine
Remove the differential expansion transmitter 182 with holder, refer to

Fig. 1-4.
Remove both rotor vibration pick-ups 183 with holders.
1744 HTGD 693 000 V0140 A
en
MAD51 -
HTGD693038V9009 -
Internal Bearing
Dismantle the thermocouples 181 from the journal bearing lower part 171.
182 172 103
3 170 181 171
183 183
BFAS0202_
3 Turbine rotor 172 Journal bearing
upper part
170 Oil shield lower part 182 Differential
expansion transmitter
171 Journal bearing lower part 183 Rotor vibration
pick-up
Fig. 1-4 Dismantling the instruments
1.4 Dismantling the journal bearing

12
MAC10
en HTGD 693 000 V0140 A

1745
1.4.1 Dismantling the bearing bracket

Loosen the bolted joint 107, 109 at the bearing bracket, refer to Fig. 1-5.
Pull out the cylindrical bolt 115 with the eyebolt 816 using the hoisting
equipment.
Lift off the bearing bracket 103 with the hoisting equipment, refer to Fig.
1-5.
WARNING
Suspended Load
danger
area.
1746 HTGD 693 000 V0140 A

en
MAD51 -
HTGD693038V9009 -
Internal Bearing
816
115
107
109
815
817
103
BFAL0301_

107 Bolt 816 Eyebolt
115 Cylindrical bolt
Fig. 1-5 Dismantling the bearing bracket
1.4.2 Dismantling the journal bearing upper part

12
MAD51
en HTGD 693 000 V0140 A

1747
Loosen and remove the socket head screws 173 in the parting plane of the
journal
bearing, refer to Fig. 1-6.
Fit eyebolts 816 , shackles 815 and attach hoisting equipment.
Lift off carefully the journal bearing upper part 172 with the hoisting
equipment.
WARNING
Suspended Load
danger
area.
Measure and record the radial clearance of the oil shield lower Test
certificate
part 170, refer to the test certificate. HTGD 499
343
HTGD 667
267
Remove the oil shield lower part 170.
Note
This is only required if the journal bearing lower part must be removed.
1748 HTGD 693 000 V0140 A

en
MAD51 - HTGD693038V9009
-
Bearing
175
815
173
816
174
172
171
170
BFAL0302_

Fig. 1-6 Dismantling the journal bearing upper part
1.4.3 Dismantling the journal bearing lower part

refer to Fig. 1-
7.
Note
en HTGD 693 000 V0140 A

1749
Turn the journal bearing lower part 171 carefully out of the bearing casing
and lift it
off with the hoisting equipment.
902
171
BFAW0101_

171 Journal bearing lower part 902 Rotor raising device
1750 HTGD 693 000 V0140 A

en
MAD51 - HTGD693038V9009 -
CHAPTER 2
RE-ASSEMBLY OF THE LP INTERNAL BEARING
en HTGD 693 000 V0140 A 1751

2 RE-ASSEMBLY OF THE LP INTERNAL BEARING

12
MAC10
Note
Preliminary remarks.
Clean the tools after use, check them for completeness and store them in
the tool
cabinet.
Caution
Do not let silicone compounds get into the turbine bearings or oil
system. Silicone
2.1 Starting point

2.1.1 Turbine
The turbine rotor is supported in the rotor raising device.
Caution
Make sure that the radial and axial positions of the turbine bearings,
relative to the
turbine, have been correctly adjusted. Check this even if the positions
were not
changed.
Note
Lubricate the running surfaces of the turbine rotor in the region of the
journal bear-
ing with a small quantity of lube oil. Ensure absolute cleanliness.
2.2 Re-installing the journal bearing

12
MAD51
2.2.1 Installing the journal bearing lower part

Attach the hoisting equipment to the journal bearing lower part 171 and
lift it onto the
rotor shaft, refer to Fig. 2-1.
1752 HTGD 693 000 V0140 A

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MAD51 - HTGD693038V9009 -
Bearing
Remove the shackle, eyebolts and also the hoisting equipment.

Turn the journal bearing lower part around the rotor shaft into the bearing
casing.
WARNING
Suspended Load
area.
Remove the Rotor raising device.
en HTGD 693 000 V0140 A

1753
902
171
BFAW0101_

171 Journal bearing lower part 902 Rotor raising
device
Fig. 2-1 Re-Installing the journal bearing lower part
2.2.2 Installing the journal bearing upper part

Attach the hoisting equipment and lift the journal bearing upper part 172,
refer to Fig.
2-2.
Align the upper part with the cylindrical pins 174 and lower it carefully.
1754 HTGD 693 000 V0140 A

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MAD51 - HTGD693038V9009 -
Bearing
WARNING
Suspended Load
area.
Tighten the socket head screws 173 according to the preten- Data sheet
sion values given in the data sheet. HTGD 630 147
Remove the shackle 815 and eyebolts 816 and also the hoisting
equipment
Re-install the oil shield lower part 170.
en HTGD 693 000 V0140 A

1755
2.2.3 Check measurements after installing the bearing

Check the radial and axial clearances of the journal bearing
Data sheet
according to the test certificate.
HTGD 667 263
HTGD 667 459
Check the radial and the axial position of the rotor in the bear-
Data sheet
ing casing according to the test certificate.
HTGD 667 274
175
815
173
816
174
172
171
170
BFAL0302_

Fig. 2-2 Re-installing the journal bearing upper part
1756 HTGD 693 000 V0140 A

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MAD51 -
HTGD693038V9009 -
Internal Bearing
2.2.4 Installing the bearing bracket

12
MAC10
Attach the hoisting equipment to the bearing bracket 103, align the
bracket with the
bearing and lower it carefully, refer to Fig. 2-3.
WARNING
Suspended Load
danger
area.
Insert the cylindrical bolts 115 with the hoisting equipment and eyebolt
816 .
Tighten the bolted joint of the bearing bracket 107 and 109, Test
certificate
refer to Fig. 2-3 and the pretension values given in the data HTGD
667 235
sheet. HTGD
667 236
WARNING
Suspended Load
danger
area.
en HTGD 693 000 V0140 A

1757
WARNING
Pressure hazard
area.
Manufac-
ture) regulations.
1758 HTGD 693 000 V0140 A

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MAD51 - HTGD693038V9009 -
Bearing
816
115
107
109
815
817
103
BFAL0301_

107 Bolt 816 Eyebolt
115 Cylindrical bolt
Fig. 2-3 Installing the bearing bracket
en HTGD 693 000 V0140 A

1759
2.2.5 Checking the Rotor jacking

Operate the jacking system and monitor the lift of the rotor shaft with a
dial gauge.
2.2.6 Installing the instruments

Install the rotor vibration pick-ups 183 with holders, refer Fig. 2- Data
sheet
4. Adjust the vibration pick-ups according to the test certificate. HTGD
667 183
Fit the thermocouples 181 in the journal bearing lower part 171.
Note
Connect all electric connections for the thermocouples and instruments at
the bear-
ing casing in accordance with the markings applied during disassembly.
1760 HTGD 693 000 V0140 A

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MAD51 - HTGD693038V9009 -
Bearing
182 172 103
3 170 181 171
183 183
BFAS0202_
part
170 Oil shield lower part 182 Differential expansion
transmitter
171 Journal bearing lower part 183 Rotor vibration pick-up
en HTGD 693 000 V0140 A

1761
2.2.7 Installing the enclosure

Attach the hoisting equipment to the lifting strap 913 on the enclosure
102, refer to
Fig. 2-5 and remove the support bars 914 .
Lower the enclosure carefully onto the support blocks with the hoisting
equipment.
Remove the Disassembly device parts from the enclosure upper part.
102
913
912
914
915
916
917
911
915
910
BGAB0105_

102 Enclosure upper Half 914 Support Bar
910 Hinge 915 Socket Screw
911 Support Upper Half 916 Washer
912 Support Upper Half 917 Nut
913 Lifting Strap
Fig. 2-5 Removing the Disassembly device from the enclosure.
Attach the hoisting equipment to the enclosure lifting eyes and lift.
Remove the
blocks and lower the enclosure upper carefully onto the lower part, refer
to Fig. 2-6.
Use taper pins 905 to align enclosure upper.
1762 HTGD 693 000 V0140 A
en
MAD51 - HTGD693038V9009 -
Bearing
Tighten all socket head screws 121 on the enclosure outer side Data sheet
in the parting plane in accordance with the pretension values HTGD 630 147
given in the data sheet.
Tighten the socket head screws 416 with washers 417 at the Data sheet
shaft seal upper part 402 and the socket head screws 121 in HTGD 630
147
the parting plane in the enclosure interior through the openings
in the enclosure in accordance with the pretension values
given in the data sheet.
Measure and record the radial clearance of the oil shield. Data sheet
HTGD 499
343
HTGD 667
267
Note
Check that all screws in the enclosure interior are inserted and tightened.
Mount the cover 116 with hexagon head bolts 117 on both sides of the
enclosure.
en HTGD 693 000 V0140 A

1763
902 121
905
902
905
815
102
416
417
117
116
121
190
169
191
402
BFAB0403_

102 Bearing casing enclosure upper 402 Shaft seal upper
part
121 Socket head screw 902 Jack screw (not
inserted)
169 Oil shield upper part 905 Taper pin
190 Hexagon head screw 815 Shackle
191 Cover
Fig. 2-6 Installing the enclosure
2.3 Closing the outer casing

1764 HTGD 693 000 V0140 A
en
MAD51 - HTGD693038V9009
-
Bearing
2.3.1 Installing the rupture diaphragm support

Put the seal 127 on the support surface at the outer casing upper half and
mount the
rupture diaphragm support 126 complete with the rupture diaphragm on the
upper
half, refer to Fig. 2-7.
Tighten the hexagon head bolts 128 according to the preten- Data sheet
sion values given in the data sheet. HTGD 630
147
BGAX0301_
A2468

126 Rupture diaphragm support 128 Hexagon head bolt
127 Seal 129 Rupture diaphragm
assembly
Fig. 2-7 Closing the outer casing
2.4 Final remarks

Note
Tighten and secure all screws and bolts without recorded Data
sheet
prestress, refer to the data sheet. HTGD 630
147
en HTGD 693 000 V0140 A

1765
Note
Re-connect all thermocouples and instruments of the turbine according to the
markings applied during disassembly and check their functioning.
them in
the tool cabinets.
HTGD693038V9009
1766 HTGD 693 000 V0140 A

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MAK80 - HTGD691883V9000 -
Rotor Turning Gear - WDE6016
MAK80 - HTGD691883V9000 -
en HTGD 693 000 V0140 A 1767

Revision History
total :
- - (26)
1768 HTGD 693 000 V0140 A en

MAK80 - HTGD691883V9000 -
Contents
1 GENERAL
INFORMATION .......................................................................
....................... 1771
1.1
Abbreviations .....................................................................
.................................. 1771
1.2 Notes on
warranty...........................................................................
..................... 1772
1.3 Functional
verification ......................................................................
.................... 1772
1.4 Terms of
delivery ..........................................................................
....................... 1772
2 SAFETY
INSTRUCTIONS ......................................................................
......................... 1773
2.1 Symbols for important instructions /
operations ................................................... 1773
2.2 Personnel
qualification......................................................................
................... 1773
2.3 Non-observance of safety
instructions................................................................. 1774
2.4 Safety
regulations .......................................................................
......................... 1774
2.5 Safety instructions for the
operator ......................................................................
1774
2.6 Safety instructions for installation and
maintenance............................................ 1775
2.7 Safety requirements for spare
parts..................................................................... 1775
2.8 General summary of safety
requirements............................................................ 1775
3 LOADING, STORAGE,
SHIPPING ..........................................................................
........ 1776
3.1
Loading ...........................................................................
..................................... 1776
3.2
Storage ...........................................................................
..................................... 1776
3.3
Shipping ..........................................................................
..................................... 1777
4
DESCRIPTION........................................................................
......................................... 1780
4.1
Construction.......................................................................
.................................. 1780
4.2 Functional
description .......................................................................
................... 1785
5 TECHNICAL
DATA ..............................................................................
............................ 1787
6 ASSEMBLY AND
INSTALLATION.......................................................................
............ 1788
6.1 Mounting
instructions ......................................................................
..................... 1788
6.2 Electrical
Installation ......................................................................
...................... 1788
7
OPERATION .........................................................................
........................................... 1789
7.1 General operating
conditions ........................................................................
....... 1789
7.2 Automatic operation from the turbine control
system........................................... 1789
en HTGD 693 000 V0140 A

1769
WP4110 & WP4140
7.3 Manual operation with the hand

lever.................................................................. 1789
7.4
Malfunctions.......................................................................
.................................. 1790
8
MAINTENANCE .......................................................................
........................................ 1790
9 SPARE PARTS LIST
(EXCERPT) .........................................................................
.......... 1791
Figures
Fig. 1 WDE6016 mounted on a TBS bearing

pedestal............................................................ 1771
Fig. 2 Loading the
WDE6016 ...........................................................................
....................... 1776
Fig. 3 Shipping of the
WDE6016 ...........................................................................
................. 1777
Fig. 4 WDE6016 variant HTGD025580
R0012........................................................................ 1780
Fig. 5 Diagram of
WDE6016............................................................................
....................... 1781
Fig. 6: HTGD351 673 Terminal plan of
WDE6016 .................................................................. 1783
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MAK80 - HTGD691883V9000
-
Rotor Turning Gear -
WDE6016
1 GENERAL INFORMATION
The WDE6016 rotor turning gear is available in only one size but four
variants for
steam turbines which may have a power output of more than 1000 MW. The 4 kW
AC motor is controlled by a frequency converter, which is directly mounted on
the
motor. The WDE6016 is tested in the workshop and can be mounted and operated
directly. Additional axial space is not necessary and subsequent installation
in exist-
ing systems is possible.
Fig. 1 WDE6016 mounted on a TBS bearing pedestal
1.1 Abbreviations
I&C Instrumentation & Control
MCC Motor control centre
KKS Kraftwerk-Kennzeichen-System
TBS Standard thrust bearing
WDE6016 Wellendreheinrichtung (rotor turning gear with
6000 Nm and 16 rpm)
en HTGD 693 000 V0140 A

1771
1.2 Notes on warranty

The WDE6016 must only be used under the field conditions, which are
described in
this instruction manual.
The manufacturer is not liable for any malfunction or damage caused by any
other
than the intended use of the WDE6016 or individual modules or parts of it.
The same
also applies to any repair or other service operation performed or attempted
by per-
sons other than duly authorized service staff. Such action will invalidate
any claim
under warranty, including for parts not directly affected.
The manufacturer is not liable for any malfunction or damage caused by
ignorance of
this instruction manual or non-observance of safety requirements, warnings
and cau-
tions. The same also applies to any consequential damages.
The WDE6016 must be operated by properly trained and well-instructed staff.
The
proper operating condition of the WDE6016 and the associated equipment must
be
verified before putting them into operation.
Any device modification, particularly the removal or replacement of device
parts or
the use of accessories from other manufacturers is not permitted. Mind that
any such
action will render all warranty claims null and void.
Annotation: Technical device upgrading by the manufacturer are subject to
change
without prior notice.
1.3 Functional verification

Functionality of every rotor turning gear (WDE6016) has been verified before
deliv-
ery. The functional verification is confirmed in a test certificate, which
was delivered
together with the equipment to the customer. Please also pay attention to
the notes
in case of shipping damages.
1.4 Terms of delivery

The general terms of delivery of ALSTOM are valid in their actual version.
1772 HTGD 693 000 V0140 A

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MAK80 - HTGD691883V9000
-
WDE6016
2 SAFETY INSTRUCTIONS
The following instructions include fundamental notes and warnings, which have
to be
observed for installation, operation and maintenance.
To fulfil the safety aspects, these instructions must be read in particular
before per-
forming any installation, operation or maintenance work.
2.1 Symbols for important instructions / operations

The following symbols are marking important manual instructions. Disregarding
these instructions may result in damage to the equipment respectively in
injury to the
operator of the equipment.
Note
This symbol indicates information, which should be especially
observed.
Caution
This symbol indicates danger to the equipment.
WARNING
This symbol indicates danger to personnel. The symbol shown warns of
dangerous electric voltage.
2.2 Personnel qualification

Properly qualified personnel must perform operation, maintenance and service
work.
The specific areas of responsibility must be observed and inspected by the
cus-
tomer.
Personnel without the specific qualification must be properly trained before
working
at the equipment. Ensure that the necessary operating instructions have been
com-
pletely understood. This includes all actions on installation, connection,
operation
and maintenance.
en HTGD 693 000 V0140 A

1773
2.3 Non-observance of safety instructions

Non-observance of the safety instructions may result in serious damage to
the
equipment and the direct environment as well as in serious injury to the
personnel. In
addition this will render all warranty claims of the manufacturer null and
void.
2.4 Safety regulations

Together with the instructions in this manual, the relevant national safety
regulations
as well as the legal directives for installation, commissioning and
operation of the
plant and the corresponding prevention of accidents regulations must be
observed.
The following are safety regulations in the EU:
DIN VDE 0100
DIN VDE 0113
EN 60204 Part 1
EN 50110-1 VDE 0105
Beyond this the personnel must observe the internal safety precautions and
regula-
tions of the company.
2.5 Safety instructions for the operator

The WDE6016 has an enclosure of type IP 54 (frequency converter is IP65).
Note
Observe the data sheets of the equipment.
WARNING
Danger to life!
Do not open electric terminal boxes. Some live units (e.g.
terminals)
carry hazardous voltages.
Switch off the WDE6016 and protect it against reclosing
before
working.
Authorized service staff must perform the work.
The safety requirements must be observed.
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MAK80 -
HTGD691883V9000 -
WDE6016
2.6 Safety instructions for installation and maintenance

At the plant, the customer is responsible for carrying out installation and
mainte-
nance work only by qualified personnel.
Note
IMPORTANT!
Switch off the WDE6016 and protect it against reclosing before
working at
the plant. Attach the following warning sign:
WARNING
High voltage/Electrical shock
Danger to life!
Do not switch on!
Personnel are working at the plant.
2.7 Safety requirements for spare parts

The manufacturer is not liable for any damage caused by unauthorized work,
particu-
larly as the result of any removal or replacement of device parts or as the
result of
using spare parts from other manufacturers than ALSTOM.
Such action will render all warranty claims null and void.
Changes and modifications to system components must be carried out by service
staff of the manufacturer or persons expressly authorized and trained by the
manu-
facturer. Use original spare parts from ALSTOM only.
2.8 General summary of safety requirements

Safety and reliability of the WDE6016 can only be guaranteed when observing
all of
the installation instructions, operation instructions and the system
parameters of the
data sheets.
en HTGD 693 000 V0140 A

1775
3 LOADING, STORAGE, SHIPPING

3.1 Loading
Weight of the WDE6016 = 341 kg
The WDE6016 must be lifted or displaced with the hoisting apparatus.
Fig. 2 Loading the WDE6016
3.2 Storage
The WDE6016 gearbox is delivered with service preservation oil. With closed
gear-
box openings (delivery condition) the corrosion protection will last approx.
6 months.
1776 HTGD 693 000 V0140 A

en
MAK80 - HTGD691883V9000
-
WDE6016
3.3 Shipping
Note
Observe the shipping dimensions and the maximum safe load of the
transporter.
Fig. 3 Shipping of the WDE6016
Please refer to the shipping documents for the exact weight. Observe the
shipping
and loading instructions on the shipping container. The following means:
Note
Fragile ware
Note
Protect from moisture
Note
Upside
Adequate loading security devices (transport belts, anti-skid devices etc.)

should be
provided during shipping.
en HTGD 693 000 V0140 A

1777
Note
IMPORTANT!
Please exactly observe our instructions in cases of shipping damage.
If
you don't observe the formal requirements the transport insurer is
not li-
able.
Note
The shipping documents contain a red information sheet, which
facilitates
handling in case of shipping damage. If this sheet is missing in the
ship-
ping documents, you can simply copy the following page.
To determine the extent of shipping damage, consult timely the commissioner
of the
transport companies, according to their relevant regulations. This
guarantees the
claims for damage in your interest.
1778 HTGD 693 000 V0140 A

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MAK80 - HTGD691883V9000 -
EXTERNALLY RECOGNIZABLE DAMAGES OR LOSSES

- Damages or losses must be attested on the way-bill by a specific note
before tak-
ing the ware. On railway transports demand a factual statement from the
railway
company. On postal transports the damage has to be attested in writing
before
taking damaged packets from the postal service.
NON RECOGNIZABLE DAMAGES
- Inform the transport company immediately and in writing about damages,
which
become visible during unpacking. Observe the following terms for
notification:
a) Postal service ..................................... Immediately (not
later than 24 hours)
after delivery by the transport company.
b) Railway company ..................................... Not later than 7
days after delive-
ryby the transport company.
c) Forwarding agency transports together with railway transports
............................... Not later than 4 days after delivery
by the transport com-
pany.
The following text is recommended for informing the transport company:
To the goods office
in ................................................................................
....................
(or postal service, forwarding agency, transport company).
The consignment with date ........................
(sender ................................)
from.............................. to .....................................
(statement of the way-bill, parcel,
signature)
has been taken without reclamation since no external damage was recognized.
However on opening the consignment the content was found to be damaged and /
or
stolen during shipping. We are of the opinion that you are responsible for the
dam-
age occurred. If you consider it necessary to inform yourself personally of
the extent
of damage, you can do this
in our
company ...........................................................................
.............................in
our
depot..............................................................................
.............. (road, number)
about the extent of damage.
In addition we would like you to inform the sender of our company by telling
us the
number of the delivery note and / or the bill number.
en HTGD 693 000 V0140 A
1779
4 DESCRIPTION
4.1 Construction
The WDE6016 is available in four variants
HTGD025580 R0011 Clockwise turning and motor on the right-hand
side
HTGD025580 R0012 Clockwise turning and motor on the left-hand
side
HTGD025580 R0021 Anti-clockwise turning and motor on the right-
hand side
HTGD025580 R0022 Anti-clockwise turning and motor on the left-
hand side

1 Manual operation 5 Frequency converter
2 Terminal boxes 6 Maintenance switch
3 Hand lever 7 Key pad with connection
cable
4 Solenoid valve
Fig. 4 WDE6016 variant HTGD025580 R0012
1780 HTGD 693 000 V0140 A

en
MAK80 - HTGD691883V9000 -
WDE6016
The WDE6016 is an electrical rotor turning gear and consists of

� Frequency converter located on top of the gear motor
� Pinion with clock- and anti-clockwise thread to be moved on the shaft
� Solenoid valve for passing lube oil (1.5 bar) into an annular chamber in
order to
build up an axial force for moving the pinion towards the turbine wheel
(engaging)
� Spring to move the pinion towards the disengaged position
� Maintenance switch to shut off the power supply to the motor
� Illuminated push-button for manual operation
� Proximity switches for manual operation (2, monitoring whether hand lever is
mounted) and engaged position of the pinion (1).
� Terminal boxes for signals (1) and solenoid valve / motor (1). The terminal
boxes
are the interfaces to the field cabling.
� Hand lever for manual operation in the case of electrical malfunctioning
� The parameter set of the frequency converter shall be stored in the key pad
E82ZBB connected with the cable E82ZWL050 (5 m) to the frequency converter.
A PC can be connected using the cable E82ZWL050, the LECOM A module
(E82ZBL-C) and an RS232 cable (EWL0020, 5 m). E82ZBL-C and EWL0020 are
not included in the standard delivery.
Fig. 5 Diagram of WDE6016
en HTGD 693 000 V0140 A

1781
KKS *) Conn. Size Designation

MAK80 / 60 P G 1/2 �� Lube oil connection
MAK80 / 61 MP G 1/2 �� Measure connection
,,Pressure under active
piston"
MAK80BP010 2 mm Orifice
MAK80EA011 -X30 el1 M20 **) Conn.: Motor feeder
MAK80EA011 -X20 el2 M20 **) Conn.: Solenoid valve
MAK80EA011 -X10 e3 M20 **) Conn.: I&C
MAK80AA015 -U01 Solenoid valve
MAK80EA011 -U01 Frequency converter
MAK80EA011 -M01 AC motor
MAK80EA011 -S20 Maintenance switch
MAK80EA011 -S21 M12 Aux. contact ,,Service
switch OFF"
MAK80EA011 -H01 M22 Push-button: Manual
operation
MAK80EA011 -H02 M22 LED: Manual operation
MAK80CG021 -S01 M12 Prox. switch ,,Pinion
engaged"
MAK80CG005 -S01 M12 Prox. switch ,,Manual
operation 1"
MAK80CG006 -S01 M12 Prox. switch ,,Manual
operation 2"
*) The KKS designations can be adapted project-specifically
**) M20 / M12 is standard. Other sizes have to be adapted on site with the
local termination
technique
1782 HTGD 693 000 V0140 A

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MAK80 - HTGD691883V9000 -
Fig. 6: HTGD351 673 Terminal plan of WDE6016
en HTGD 693 000 V0140 A 1783

& WP4140
Blank Page
1784 HTGD 693 000 V0140 A en

MAK80 -
HTGD691883V9000 -
WDE6016
4.2 Functional description

Before activating the WDE6016, the lube and jacking oil systems have to be
switched on and the rotor speed must be below 4 rpm. The automatic program
(lo-
cated in the turbine control system) then activates the solenoid valve and
lube oil,
(1.5 bar) enters the annular chamber of the pinion hub and shifts it towards
the tur-
bine wheel. At the same time the electric motor turns the pinion forward and
back-
ward until the pinion engages with the wheel. A proximity switch monitors the
en-
gaged pinion position. Locally, the LED in the push-button lights up. If the
engaging
process lasts too long it is stopped and an alarm issued. To avoid damage to
the
gear the motor torque is set to a minimum. After engaging it is set back to
100%.
The activated proximity switch releases the frequency converter feeding the
motor in
order to build up the breakaway torque. To avoid damage to the turbine this
torque
was limited during commissioning by limiting the permissible motor current at
the fre-
quency converter. If the rotor does not rotate, the "Release" signal of the
frequency
converter gets lost, the WDE6016 is stopped and an alarm issued. The motor
re-
verses and the pinion returns to the disengaged position.
If the turbine shaft begins to rotate, the frequency converter accelerates
the rotor to a
speed of 16 rpm by means of a vector controller integrated in the frequency
con-
verter. The vector controller is based on a motor model adapted by the
nominal data
and the actual winding resistance of the motor. Measuring the motor voltage
and cur-
rent, the vector controller optimally controls the motor during acceleration
and
steady-state operation.
The WDE6016 can be switched off in three ways:
1. During start-up when the turbine rotor rotates faster than the WDE6016.
2. To end the turn operation the motor will be switched off.
3. In case of a malfunction the motor will turn in opposite direction.
In all cases the thread in the shaft of the WDE6016 disengages the pinion
mechani-
cally from the turbine wheel. After disengaging a spring pushes the pinion
into the
disengaged position.
en HTGD 693 000 V0140 A
1785
In the case of power loss, the motor can be turned with a hand lever. The
mainte-
nance switch has to be set into the OFF-position and the motor hood removed.
Pressing the push-button for manual operation the LED lights up and the
solenoid
valve is activated for a short time (typical 20 sec). If there is also no
power supply to
the solenoid, the valve can be activated by the manual override of the
valve. The
WDE6016 is returned to the automatic mode by re-mounting the motor hood and
turning the maintenance switch into the ON-position.
1786 HTGD 693 000 V0140 A

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MAK80 - HTGD691883V9000 -
5 TECHNICAL DATA
Nominal turbine breakaway torque 6000 Nm
Number of teeth 132
Modulus 8
Material St575
Drawing number of turbine wheel HTGD130815
WDE6016
Drawing number of WDE6016 HTGD025580
Number of pinion teeth 49
Modulus 8
Material of pinion St450
Thread left/right
Motor position left or right
Turning speed 16 rpm
Weight 341 kg
Oil demand 5 l/min
Oil pressure 1.5 bar
Dimensions (width x height x depth) 949 x 536 x 652 mm
Gear motor (Lenze)
Frequency converter type E82MV752_4B
- Nominal grid voltage 320 to 550 VAC
- Nominal grid frequency 45 to 65 Hz
- Power 7.5 kW
- I/O module type E82ZAFAC001
- Handheld E82ZBB
- Connection cable to handheld E82ZWL050, 5 m
- Protection class IP 65
Motor type MDXMA3M 112-22
- Nominal power at 50 Hz 4 kW
- Nominal speed at 50 Hz 1430 rpm at 50 Hz
- Nominal voltage at 50 Hz 230V AC
- Nominal current 8.5 A
- Enclosure IP 55
- Insulation class F
- PTC resistor 1 piece
Gearbox type GKS07-3M HAR 112-22
- Max torque (short-time) 2800 Nm
- Lubricant CLP HC320 (synthetic oil) 6.4 litre
- Oil change 16'000 h or 3 years
en HTGD 693 000 V0140 A 1787

6 ASSEMBLY AND INSTALLATION

6.1 Mounting instructions
1. Attach the WDE6016 casing to the bearing cover and slightly fix it with 2
screws.
2. Open the cover of the gearbox and check if the pinion is disengaged.
3. Check contact pattern. The flank clearance (between 0.3 and 1 mm) will be
ad-
justed by the gaskets to be placed between the WDE6016 and the bearing
cover.
� 1 gasket, thickness 2 mm = standard centre-to-centre
� 1 gasket, thickness 1 mm = standard centre-to-centre - 1 mm
� 2 gaskets thickness 3 mm = standard centre-to-centre + 1 mm
4. Fix the WDE6016 casing at the turbine casing with two locating plugs.
5. Install the oil inlet
6.2 Electrical Installation

Note
Installation or the electrical connection of the rotor turning
gear WDE6016
must be performed by qualified electricians. Observe the relevant
regula-
tions.
1. Install cables at the connections el1, el2 and el3, see Fig 5.
2. Switch on the maintenance switch
1788 HTGD 693 000 V0140 A

en
MAK80 - HTGD691883V9000
-
WDE6016
7 OPERATION
Note
The WDE6016 is intended to operate with the electronic turbine
control
system. Local operation is foreseen in emergency cases only.
7.1 General operating conditions

� The MCC cabinet is supplied with the specified voltage.
� The mains switch on the MCC cabinet is set to position "ON".
� The motor hood is closed.
� The lube oil and jacking oil systems are in operation.
� The maintenance switch is ON.
� The motor hood is mounted.
7.2 Automatic operation from the turbine control system

1. Start the WDE6016 from the turbine control system.
2. The engagement process is started by activating the solenoid valve and
turning
the pinion forward and backward until the proximity switch is activated.
If the pin-
ion is not engaged within a certain time the program stops and an alarm
issued.
3. After engaging, the motor accelerates the rotor to 16 rpm. The breakaway
torque
is limited to avoid damage to the system. If the turbine shaft does not
start to ro-
tate within a certain period of time the program stops and an alarm is
issued.
4. The vector controller in the frequency converter of the WDE6016 controls
the tur-
bine shaft speed.
5. The WDE6016 can be shut off either by the control system or mechanically
when
the rotor rotates faster than the WDE6016.
7.3 Manual operation with the hand lever

In the case of AC loss the rotor can be turned manually via the hand lever
1. Set the maintenance switch to "OFF" position.
2. Remove the motor hood
3. Pressing the push-button the LED will light up and the solenoid valve is
activated
electrically or manually by emergency manual override.
4. Turn the motor shaft until the pinion is engaged (LED lights up
continuously).
en HTGD 693 000 V0140 A

1789
5. Attach the hand lever to the adapter of the motor shaft and turn it.
6. Close the motor hood.
7. Set the maintenance switch to "ON".
7.4 Malfunctions
Malfunction Cause/action/signalisation
Power failure - Alarm in control room
- Measure the current in the 3 phases of
the motor
- Check fuses and earthing contacts
- Maintenance switch in OFF-position
High motor temperature - Alarm in control room
- Check if motor turns with difficulties
Defective solenoid valve - Replacement of the solenoid valve
Malfunction of proximity switch - Replacement of the proximity switch
Turbine shaft does not rotate - Alarm in control room
8 MAINTENANCE
The rotor turning gear must be maintained regularly.
ALSTOM recommends observing the following:
� The roller bearings are continuously lubricated by oil, to be checked on
every
overhaul by authorised service staff.
� For safety reasons the electronic signals of the proximity switches must
be veri-
fied on every overhaul by authorised service staff.
� The gear oil must be exchanged every 16'000 h or after 3 years at the
latest.
1790 HTGD 693 000 V0140 A

en
MAK80 -
HTGD691883V9000 -
WDE6016
9 SPARE PARTS LIST (EXCERPT)

We only give a warranty for spare parts and accessories supplied by ALSTOM.
Ident-no. Designation Quantity
*)
tot **)
2y 5y
HTGD025580R *) WDE6016 complete 1
- -
HTGD025580P0005 Pinion 1
1 1
HTGD025580P0006 Bushing (together with the shaft only) 1
1 1
HTGD025580P0007 Bearing 1
1 1
HTGD025580P0007 Shaft (together with the bushing only) 1
1 1
HTGD025580P0010 Cover sealing 1
1 2
HTGD025580P0011 Spring 1
1 2
HTGD025580P0015 Sealing 1 mm 1
1 2
HTGD025580P0016 Sealing 2 mm 1
1 2
HTGD025580P0020 Proximity switch 3
2 4
HTGD025580P0103 Roller bearing 22216 1
1 2
HTGD025580P0104 Roller bearing 22211 1
1 2
HTGD025580P0112 Solenoid valve 1
1 2
HTGD025580P0113 Lever 1
1 2
HTGD492324P0010 Gear motor with frequency converter 1
1 1
HTGD492324P0021 Frequency converter, E82MV752_4B 1
1 2
HTGD492324P0022 Function module, E82ZAFAC001 1
1 2
HTGD492324P0031 Connection cable, E82ZWL050, 5 m 1
1 2
HTGD492324P0032 Handheld E82ZBB 1
1 2
*) R = Rubrik number see chapter 4.1
**) tot = number of parts within the WDE6016
2y / 5y = recommended spare parts for 2 / 5 years

HTGD691883V9000
en HTGD 693 000 V0140 A

1791
Blank Page
1792 HTGD 693 000 V0140 A en

MAV - HTGD693010V9024 -
Technical Description of the Lube and Control Oil Supply Systems
with integral pressure generation for the jacking oil
system
MAV - HTGD693010V9024 -
Technical Description of the Lube
and Control Oil Supply Systems
with integral pressure generation for the jacking oil system
en HTGD 693 000 V0140 A

1793
Revision History
total :
- - (18)
1794 HTGD 693 000 V0140 A en

MAV - HTGD693010V9024 -
Technical Description of the Lube and
Control Oil Supply Systems
with integral pressure
generation for the jacking oil system
Contents
1
CONCEPT............................................................................
............................................................1797
2 DESIGN OF THE LUBE OIL
SUPPLY.............................................................................
................1799
2.1 Main lube oil

system ............................................................................
................ 1799
2.1.1 Oil
tank ..............................................................................
...................... 1800
2.1.2 Lube oil
filter ............................................................................
................ 1802
2.1.3 Temperature
control ...........................................................................
..... 1802
2.1.4 Oil conditioning
plant .............................................................................
.. 1802
2.1.5 Safety
functions..........................................................................
............. 1802
2.2 Auxiliary oil
system ............................................................................
.................. 1803
2.3 Emergency oil
system.............................................................................
............. 1803
2.4 Jacking oil
system.............................................................................
................... 1803
3 DESIGN OF THE CONTROL OIL
SUPPLY ............................................................................
........1804
3.1 Pressure generation for the control oil

system..................................................... 1805
3.2 Control oil
filter ............................................................................
......................... 1805
3.3
Accumulator .......................................................................
.................................. 1805
4
SUPERVISION........................................................................
.........................................................1805
4.1
General ...........................................................................
..................................... 1805
4.1.1 Temperature
supervision........................................................................
. 1806
4.1.2 Pressure supervision in the lube oil
system ............................................ 1807
4.2 Control oil
system ............................................................................
.................... 1808
4.2.1 Temperature
supervision........................................................................
. 1808
4.2.2 Pressure supervision in the control oil
system ........................................ 1808
4.2.3 Check of the
accumulator........................................................................
1809
en HTGD 693 000 V0140 A

1795
& WP4140
Figures
Fig. 1-1 Arrangement of the tank with external

connections ................................................... 1798
Fig. 2-1 Components of the supply
systems ...........................................................................
1799
Fig. 2-2 Arrangement of pumps and
filters ...........................................................................
... 1801
Fig. 3-1 Components of the control oil
supply .........................................................................
1804
Fig. 4-1 Temperature
supervision........................................................................
.................... 1806
Fig. 4-2 Lube oil pressure
supervision........................................................................
............. 1807
Fig. 4-3 Control oil pressure
supervision .......................................................................
.......... 1809
Lubricating and control oils for turbines
P & ID Lube oil system
P & ID Control and protection system
Component descriptions
1796 HTGD 693 000 V0140 A

en
MAV - HTGD693010V9024 -
Technical Description of the Lube and Control Oil Supply
Systems
with integral pressure generation for the jacking oil
system
1 CONCEPT
The present concept of the combined lube and control oil supply ensures
reliable
supply for all components under all operating conditions.
If design permits and if it is useful, all operable components are mounted on
the
common oil tank, shown in Fig. 1-1, so that the necessary safety measures can
be
applied efficiently.
en HTGD 693 000 V0140 A

1797
Fig. 4-2
MAV02/054
MAV02/040
Fig. 2-2
MAV02/053
MAV02/051
Fig. 4-3
MAV02/052
MAV02/050
MAV02/055 Fig.
2-1
MAV02BB001
MAV02/059
CQAA0801_
Fig. 3-1
A2125
MAV02/040 Exhaust air, oil vapour MAV02/050 Pressure

pipe to oil cool-
exh. ers
MAV02/051 Suction pipe, main oil MAV02/052 Pressure
pipe, main oil
pump pump
MAV02/053 Pressure pipe from oil MAV02/054 Lube oil
distributor
coolers
MAV02/055 Return header MAV02/059 Drain
connection
MAV02BB001 Oil tank MAV22AC001 Oil
cooler(not shown)
MAV22AC002 Oil cooler(not shown) MAV91AT001 Oil
conditioning plant(not
shown)
Fig. 1-1 Arrangement of the tank with external connections
1798 HTGD 693 000 V0140 A

en
MAV -
HTGD693010V9024 -
Technical Description of the Lube and Control Oil
Supply Systems
with integral pressure generation for the
jacking oil system
2 DESIGN OF THE LUBE OIL SUPPLY

2.1 Main lube oil system
During normal operation the turbine-shaft-driven main oil pump (MAV21AP011)
sup-
plies the turbine bearings with lube oil. The lube oil is fed into the system
before the
filters and coolers. The pressure pipe of the pump is equipped with a check
valve
MAV21AA001 with calibrated bypass orifice for returning the oil from the
auxiliary or
emergency oil system during turbine start-up and shutdown.
The system pressure is set with the pressure control valve MAV40DP001. To
pre-
vent the pressure losses in the oil coolers and filters from affecting the
feed pressure
for the bearings, the impulse line for the pilot control of the pressure
control valve is
connected downstream of the filters and coolers, seen in the direction of
flow.
MAX11CP501 MAX11CP031 MAV21AA001
MAX11DP001
MAV70AT001 MAV02CL001 MAV21AT021 MAV22DT001
MAV21AT001 MAX11AT001 MAV21AT031

MAV40DP001
MAX11AT002
CQAA0802_
A2123
MAV02CL001 Level switch MAV21AA001 Check valve

MAV21AT001 Suction basket, main oil MAV21AT021 Suction
basket, aux. oil
pump pump
MAV21AT031 Suction basket, em. oil MAV22DT001 Temperature
controller
pump
MAV40DP001 Pressure control valve MAV70AT001 Return
strainer
MAX11CP031 Pressure switch MAX11CP501 Pressure
gauge
MAX11DP001 Pressure control valve
Fig. 2-1 Components of the supply systems
en HTGD 693 000 V0140 A

1799
2.1.1 Oil tank

The welded oil tank MAV02BB001 which is the common tank for the lube and
con-
trol oil systems is so dimensioned that the returning oil is stilled
adequately before it
is once again pumped into the cycles.
The oil vapour exhauster MAV02AN001 removes the oil vapours in the tank and
pipes. The partial vacuum in the return pipes and the bearing pedestals
helps to pre-
vent the oil vapours from escaping from the bearing seals.
The air and oil vapour mixture that is removed by the extractor is replaced
by fresh
air pulled in through the air filter MAV02AT001.
A level switch MAV02CL001 with visual indication monitors the minimum and
maxi-
mum oil levels.
1800 HTGD 693 000 V0140 A

en
MAV -
HTGD693010V9024 -
Systems
with integral pressure generation for the jacking
oil system
MAX11AP001 MAX11DP001 MAV21AP031 MAV23CP001

MAV02AT001 MAX11AP002 MAV21AP021
MAV23AT001
MAV50CP001
MAX43
MAX44AA001
MAX13CP001 MAV02CL001
MAV40DP001
MAV50DP001 MAV50AE001
MAX13AT001 MAV02AN001 MAV50AP001

MAV22DT001
CQAA0805_
A3184
MAV02AT001 Air filter MAV21AP021 Auxiliary oil

pump
MAV21AP031 Emergency oil pump MAV22DT001 Temperature
controller
MAV23AT001 Lube oil filter MAV23CP001 Differential
pressure
switch
MAV40DP001 Pressure control valve MAV50AE001 Drive motor
MAV50AP001 Jacking oil pump MAV50DP001 Pressure
limiting valve
MAX11AP001 Control oil pump MAX11AP002 Control oil
pump
MAX11DP001 Pressure control valve MAX13AT001 Control oil
filter
MAX13CP001 Differential pressure MAX43 Trip unit
switch
MAX44AA001 Sequence valve MAV50CP002 Oil pump
pressure gauge
MAV02AN001 Oil vapour exhauster
Fig. 2-2 Arrangement of pumps and filters

en HTGD 693 000 V0140 A
1801
2.1.2 Lube oil filter

The lube oil filter MAV23AT001 is a change-over double filter. Each filter
side has a
capacity of 100%. One filter side is in operation, the other on standby.
If the p supervisory equipment MAV23CP001 issues an alarm, change-over to
the
standby filter side is required. In the case of an increase in differential
pressure, the
bypass valve, integrated in the filter, opens and the oil flows without
being filtered.
The filter has an automatic continuous vent.
2.1.3 Temperature control

The friction heat produced by the turbine bearings and the pumps and the
heat that
the lube oil absorbs from the turbine rotors warm up the lube oil in the
tank. This heat
is discharged via the water-cooled oil coolers MAV22AC001 or MAV22AC002. If
the
oil coolers are connected in parallel, the continuous vent must be
operating so that
the standby cooler is always ready for operation.
The temperature controller MAV22DT001 mixes cooled and uncooled oil in such
a
way that the temperature of the oil fed to the bearings complies
continuously with the
operating value.
For safety reasons the temperature is controlled without changing the
cooling water
flow to the oil coolers.
2.1.4 Oil conditioning plant

To ensure trouble-free operation the lube oil is continuously conditioned
in an oil
conditioning plant MAV91AT001, located in the secondary flow.
Caution
Only ALSTOM-tested and approved "Lubricating and control oils for turbines"
may
be used for operating the lube and control oil systems.
2.1.5 Safety functions

All safety functions that cause a turbine trip due to critical operating
conditions are so
designed that an alarm is given first.
Appropriate actions must ensure that incorrect switching or defective
instruments do
not initiate a trip.
Caution
The turbine must be shut down immediately in the case of a failure of the
main oil
pump or an oil level below the low level.
1802 HTGD 693 000 V0140 A
en
MAV -
HTGD693010V9024 -
Systems
oil system
2.2 Auxiliary oil system

A three-phase AC centrifugal pump MAV21AP021 supplies the auxiliary oil and
en-
sures lubrication of the bearings during turbine start-up and shutdown and
turning
gear operation.
A check valve is fitted in the pressure pipe of the pump, preventing backflow
of the
oil when the main oil pump operates at full capacity and the auxiliary pump
is out of
operation.
As in the case of the main oil pump, the supply to the system is located
upstream of
the filters and coolers.
2.3 Emergency oil system

A DC centrifugal pump MAV21AP031 supplies the emergency oil system. Its
capac-
ity is adequate to ensure lubrication of the bearings during turbine shutdown
and in
the case of a failure of the auxiliary oil pump or collapse of the three-
phase AC sup-
ply.
A check valve is fitted in the pressure pipe of the pump, preventing backflow
of the
oil when the main or auxiliary oil pump operates at full capacity and the
emergency
pump is out of operation.
Due to the lower capacity the supply to the system is located downstream of
the fil-
ters and coolers.
2.4 Jacking oil system

A three-phase AC axial piston pump MAV50AP001 supplies the jacking oil
system.
This pump is driven by the motor MAV50AE001.
A pressure limiting valve MAV50DP001 limits the pressure in the jacking oil
system
to a value corresponding to the operating data. The pump is supplied from the
com-
mon main oil system downstream of the lube oil filter.
The high pump pressure permits the formation of a hydrostatic oil film in the
turbine
bearings and prevents metallic contact of the bearing surfaces during turbine
start-up
and shutdown and during turning gear operation when a hydrodynamic oil film
is not
yet available.
The high pump pressure lifts the turbine rotor and reduces the break-away
torque
especially during turbine start-up. The pump is supplied from the common
piping
system of the lube oil supply. Separate pipes with small cross-section lead
from the
pump to the different bearings in order to transfer efficiently the high
pressure.
The jacking oil is returned via the piping of the main oil supply.
The different volume flows to the bearings are set at the flow control
valves, mounted
directly on each bearing pedestal.
For safety reasons the pump for the jacking oil system is switched off
automatically if
the pressure in the lube oil system drops below 20% of the operating value.
en HTGD 693 000 V0140 A

1803
3 DESIGN OF THE CONTROL OIL SUPPLY

All components in the hydraulic part of the central control and safety
system are
supplied with control oil from the oil tank which is the common tank for the
control
and lube oil systems.
The components for temperature control and supervision, oil conditioning and
level
supervision are assigned to the main lube oil supply.
MAX11AP002
MAX13AT001
MAX11AP001 MAX13CP001
MAV15BB001
MAV15DP001
MAV02GD002
MAV02GD003 MAX15AA001 MAX15CP001 MAV02CT001

CQAA0304_
MAV02CT001 Dial thermometer MAV02GD002 Terminal box
MAV02GD003 Terminal box MAX11AP001 Control oil pump
MAX11AP002 Control oil pump MAX13AT001 Control oil
filter
MAX13CP001 Differential pressure MAX15AA001 Safety valve
switch
MAX15BB001 Accumulator MAX15CP001 Pressure gauge
MAX15DP001 Pressure limiting valve
Fig. 3-1 Components of the control oil supply
1804 HTGD 693 000 V0140 A

en
MAV - HTGD693010V9024
-
Systems
oil system
3.1 Pressure generation for the control oil system

The identical three-phase AC screw-type pumps MAX11AP001 and MAX11AP002
generate the pressure for the control oil system. One of the pumps is in
operation,
the other on standby. Both pumps are taken into service periodically and
alternately.
If the pump in operation fails, the pressure switch MAX11CP031 automatically
starts
the standby pump. The required system pressure is kept at the operating value
by
the pressure control valve MAX11DP001.
3.2 Control oil filter

The control oil filter MAX13AT001 is a change-over double filter. Each filter
side has
a capacity of 100%. One filter side is in operation, the other on standby.
If the p~ supervisory equipment MAX13CP001 issues a differential pressure
alarm,
change-over to the other filter side is required. In the case of an increase
in differen-
tial pressure the bypass valve integrated in the filter opens and the oil
flows without
being filtered.
The filter has an automatic continuous vent.
3.3 Accumulator
The accumulator MAX15BB001, precharged with nitrogen, smooths pressure fluc-
tuations in the control oil system and maintains the pressure if large
volumes are re-
quired for a short time or when switching over from one pump to the other.
A pressure limiting valve MAX15DP001 protects the accumulator against
excessive
pressure. The safety valve MAX15AA001 permits separation of the accumulator
from the system for carrying out maintenance work, precharging the
accumulator
with nitrogen or relieving it.
4 SUPERVISION
4.1 General
Special attention must be paid to the supervision of the systems, function
groups and
the values adjusted during commissioning.
Especially instruments with remote transmitters for indicating, switching and
tripping
functions. Furthermore, all visual indicators. Greater changes of the
displays at
thermometers, pressure gauges and inspection glasses indicate irregularities.
Note
The oil outlet temperature at the bearings is an important criterion for
correct func-
tioning of many components.
en HTGD 693 000 V0140 A

1805
4.1.1 Temperature supervision

A dial thermometer MAV02CT001 is fitted in the tank MAV02BB001 for
supervising
the oil temperature in the oil tank.
Another dial thermometer MAV40CT001 is installed in the lube oil
distributor
MAV02/054 for supervising the oil temperature after the coolers and
filters.
A temperature remote transmitter MAV40CT002 is fitted at the same point for
evaluation in the control room and for switching functions.
MAV40CT002 MAV23AT001
MAV23CP001
MAV40CT001
MAV02GD001
CQAA0305_
MAV02GD001 Terminal box MAV23AT001 Lube oil filter
MAV23CP001 Differential pressure MAV40CT001 Dial thermometer
switch
MAV40CT002 Temperature transmitter
Fig. 4-1 Temperature supervision
1806 HTGD 693 000 V0140 A

en
MAV -
HTGD693010V9024 -
Systems
oil system
4.1.2 Pressure supervision in the lube oil system

Pressure transmitters, see Fig. 4-2, are mounted on the oil tank for
supervising the
pressure in the lube oil system and for actuating the electrically driven
lube oil pumps
during start-up, shutdown and turning gear operation or in the case of a
pressure
loss in the system.
MAV40AA503 Test valve MAV40AA504 Test valve

MAV40AA505 Test valve MAV40CP003 Pressure
transmitter
MAV40CP004 Pressure transmitter MAV40CP005 Pressure
transmitter
MAV40CP503 Pressure gauge MAV40CP504 Pressure
gauge
MAV40CP505 Pressure gauge
Fig. 4-2 Lube oil pressure supervision
en HTGD 693 000 V0140 A

1807
The three pressure transmitters MAV40CP003/004/005 are compiled in a logic

and
actuate the auxiliary and emergency oil pumps in a 2-out-of-3 selection in
the case of
a pressure drop in the lube oil system.
When the lube oil pressure drops to 60% of the operating value or below,
referred to
the turbine shaft position, the turbine is tripped and the auxiliary oil
and jacking oil
pumps are started immediately; the emergency oil pump is switched on with a
delay.
If the mean value of the three pressure transmitters is 40% of the
operating value or
less, the turbine is tripped and the auxiliary oil, emergency oil and
jacking oil pumps
are started immediately without delay. The auxiliary and emergency oil
pumps,
started this way, can only be switched off at turbine standstill.
For safety reasons the pump for the jacking oil supply is switched off
automatically
when the pressure in the lube oil system falls below 20% of the operating
value.
The pressure transmitters can be tested during operation with the test
valves
MAV40AA503/504/505.
Three pressure gauges MAV40CP503/504/505 are available for visual
inspection.
A pressure gauge is provided for visual inspection of the jacking oil pump
pressure
MAV50CP001, refer to Fig. 2-2.
4.2 Control oil system

4.2.1 Temperature supervision
The control oil temperature is supervised with the same devices and
instruments as
the lube oil.
4.2.2 Pressure supervision in the control oil system

A pressure gauge MAX11CP501 is fitted after the control oil filter
MAX13AT001 for
checking visually the pressure in the control oil system.
Pressure transmitters, see Fig. 4-3, are mounted on the oil tank for
supervising the
pressure in the control oil system.
The three pressure transmitters MAX44CP001/002/003 are compiled in a logic
and
cause a turbine trip in a 2-out-of-3 selection by closing the supply valves
for the
steam turbine in the case of a pressure drop in the control oil system.
The central safety system included in the control oil system operates
according to
the binary logic and recognises only two operating situations:
Operation ON full pressure in the control oil system
Operation OFF no pressure in the control oil system
1808 HTGD 693 000 V0140 A
en
MAV -
HTGD693010V9024 -
Systems
oil system
MAX44CP001 MAX44CP002 MAX44CP003
MAX44AA301 MAX44AA303
MAX44AA302
CQAA0307_
MAX44AA301 Test valve MAX44AA302 Test valve
MAX44AA303 Test valve MAX44CP001 Pressure
transmitter
MAX44CP002 Pressure transmitter MAX44CP003 Pressure
transmitter
Fig. 4-3 Control oil pressure supervision
The pressure transmitters can be tested during operation with the test
valves
MAX44AA301/302/303.
4.2.3 Check of the accumulator

A pressure gauge MAX15CP001 is mounted on the safety valve MAX15 AA001 for
inspecting visually the precharging pressure at the accumulator MAX15BB001.
en HTGD 693 000 V0140 A

1809
Blank Page
HTGD693010V9024
1810 HTGD 693 000 V0140 A en

MAV/MAX - HTGD090117V0001W - Lubricating
and Control Oils
for Gas and Steam Turbines
Specification and supervision
MAV/MAX - HTGD090117V0001W -
Lubricating
and Control Oils
en HTGD 693 000 V0140 A 1811

Revision History
Total No. of
document pages:
N 97-10-21, Extension of content, re-structuring of the text
-
P 98-02-11, Oil designations from Castrol have been changed
-
Q 99-06-16, Additional requirements and oil brands
-
R 00-05-17, Cleanliness class ISO 4406 changed to new standard, sev-
-
eral oil suppliers added
S 02-10-01, Name changed to ALSTOM, Section 2.1 deleted
-
(exclusion of zinc), properties adapted to ALSTOM Group,
supervision of impurities every month.
Checklist included. Oil suppliers added.
T 04-01-10, Oil suppliers added, remark regarding Finspong deleted,
20
table in Fig. 1, changed
U 05-07-20, Oil suppliers added
20
V 07-11-30, Standards in Fig. 1 & 3 updated, page 12: standard
20
NAS 1638 deleted, standard SAE 749 changed to
SAE AS4059, oil suppliers added
W 07-04-10 Standards in Fig. 1 & 3 updated, oil suppliers updated
(20)
1812 HTGD 693 000 V0140 A

en
MAV/MAX
- HTGD090117V0001W - Lubricating
and Control Oils
Contents
5
GENERAL ...........................................................................
.............................................................1815
6 SCOPE OF
APPLICATION........................................................................
......................................1815
6.1 Viscosity
classes............................................................................
...................... 1815
6.2 Terms of
delivery ..........................................................................
....................... 1815
6.3 Notes on acceptance and first filling of the lube oil
tank ...................................... 1816
6.4
References.........................................................................
.................................. 1816
6.5
Properties.........................................................................
.................................... 1816
7
SUPERVISION........................................................................
.........................................................1820
7.1
Sampling ..........................................................................
.................................... 1821
7.2 Explanatory notes on the
tables...........................................................................
1821
8 REFILLING THE OIL
TANK ..............................................................................
...............................1823
9 SELECTION OF THE OIL
SUPPLIER...........................................................................
..................1823
9.1 Tested lube and control

oils ..............................................................................
... 1823
9.2 Untested lube and control
oils..............................................................................
1827
10
CHECKLIST .........................................................................
............................................................1829
en HTGD 693 000 V0140 A
1813
WP4110 & WP4140
Figures
Fig. 1 Specification
table .............................................................................
............................ 1817
Fig. 2 Viscosity
characteristics ...................................................................
............................. 1819
Fig. 3
Supervision........................................................................
............................................ 1820
Fig. 4 Purity classes as per ISO
4406 ..............................................................................
....... 1822
Fig. 5 Purity classes as per SAE
AS4059 ............................................................................
... 1822
Fig. 6 ALSTOM-tested lube and control oils as of April
2009.................................................. 1826
1814 HTGD 693 000 V0140 A

en
Lubricating
and Control
Oils
for Gas and Steam
Turbines
Specification and
supervision
1 GENERAL
This specification lays down the requirements, test methods and terms of
delivery for
lubricating (lube) and control oils, which ALSTOM uses in steam and gas
turbines.
The mineral oils in accordance with this specification are refined mineral
oils with
additives, which increase the resistance to ageing and improve the protection
against corrosion. Small quantities of other additives may also be added to
achieve
the required properties.
Mineral oils in accordance with this specification can be used in the lube
and control
oil systems of turbomachinery.
Note
It is usually not permitted to use mineral oil as control oil in hydraulic
high pressure
systems with a pressure > 120 bar!
2.1 Viscosity classes

Mineral oils of viscosity classes ISO VG 32 and 46 are usually used for steam
or gas
turbines.
ALSTOM normally uses viscosity class ISO VG 46 if the bearing oil inlet
temperature
is between 40 �C and 50 �C (104 �F and 122 �F).
Mineral oils of viscosity class ISO VG 32 can be used without problems up to
a bear-
ing oil inlet temperature of 45 �C (113 �F). These mineral oils are less
suitable for
turbosets with higher bearing oil inlet temperatures.
The use of mineral oils of viscosity class ISO VG 68 is possible with very
high bear-
ing oil inlet temperatures.
The ALSTOM Engineering Department responsible has to be principally consulted
for approving the viscosity class.
2.2 Terms of delivery

Depending on the agreement made between supplier and customer, the oil is
sup-
plied in tank cars or in clean, solid and dry barrels. The following minimum
informa-
tion has to be provided in a legible and durable manner on each barrel:
� Designation of type and viscosity class
� Identification of product and supplier
� Charge or delivery number
en HTGD 693 000 V0140 A

1815
Note
When placing the order, a test certificate has to be requested from the
supplier for
the supplied mineral oil.
The delivery must not be accepted if this condition is not fulfilled.
2.3 Notes on acceptance and first filling of the lube oil tank
The check of and procedure for acceptance on delivery and first filling of
the lube oil
tank are laid down in the checklist to be completed.
A copy of this checklist has to be sent to the ALSTOM Project Manager.
2.4 References
ISO 6743 part 5 Lubricants, industrial oils and related
products Class L-
Classification-Part 5 Family T (Turbines)
ISO 3448 Industrial liquid lubricants-ISO viscosity
classification
ISO 4406 Hydraulic Fluid Power-Fluids - Method for
coding level of
contamination by solid particles
ISO 8068 Petroleum products and lubricants - Petroleum
lubricating oils
for turbines, categories ISO-L-TSA and ISO-L-
TGA-
Specifications
DIN 51519 ISO-Viscosity classification for liquid
industrial lubricants
2.5 Properties
When checking an approx. 10 cm thick oil film in transilluminating light,
the oil shall
be bright and clear and free of visible foreign matter. The additives must
not have
negative effects on the materials of the oil system.
The table in Fig. 1 lists the limit values for the most important properties
of the min-
eral oils and the approved test methods.
The viscosity characteristic in Fig. 2 shows the viscosity/temperature
correlation.
1816 HTGD 693 000 V0140 A

en
MAV/MAX -
HTGD090117V0001W - Lubricating
and Control Oils

for
Gas and Steam Turbines
ISO - viscosity class

Test method as per9)
Requirements1)
ISOVG32 ISOVG46 ISOVG68
ISO ASTM
Viscosity at
32 � 10% 46 � 10% 68 � 10%
3104 D445
40�C mm2 / s2)
Viscosity index3) > 90
2909 D2270
900
3675
Density at 15 �C 880 kg/m3
D 1298
kg/m3
12185
Flash point c.o.c. 200�C 200�C
2592 D 92
4)
Pour point - 9 �C - 6 �C
3016 D 97
Zinc content 5 ppm
Optional
Without EP add. 0.2 mg KOH / g
Acid number
6618 D 664 D974
With EP additive 0.3 mg KOH / g
Air release at 50 �C 4 min 7 min
9120 D 3427
Foaming characteristic at At the beginning < 300/50/300 ml
6247 D 892
24 / 93.5 / 24 �C After 5 minutes 0/0/0 ml
Demulsibility after steam
< 300 sec. DIN 51589 Part 1
treatment 5)
Water separability
<30 min
6614 D 1401
40 - 37 - 3
Class --/18/15 as per ISO 4406
Purity
4406
Class 9 as per SAE AS4059
Water content < 200 ppm
12937
Increase in acid number
Qxidation stability TOST 6)
4263-1 D 943
after 2000h <1mg KOH/g
Oxidation stability RPVOT 7) > 300 min
D 2272
Copper corrosion
Max. level up corrosion 2
2160 D 130
at 100�C/ 3 hours
Anti-corrosion characteristic
Method B passed
7160 D 665
against steel
Load carrying capacity Fail level 8 only for turbines
14635-1 D 5182
FZG normal test A/8.3/908) with gear
Level I: at least 93%,
Filterability
13357-2
Level II: at least 85%
Fig. 1 Specification table
en HTGD 693 000 V0140 A

1817
Notes on the table in Fig. 1

1)
For turbine types that are presently available. If turbines are
operated with oils
that do not comply with this specification but do not cause problems,
the oil filling
can be left.
2)
ALSTOM normally uses viscosity ISO VG 46. The viscosity must however be
de-
fined for each plant separately, depending on the oil temperature to be
expected.
3)
The viscosity index (VI) is a measure of the viscosity/temperature
correlation.
The requirement for the index is fulfilled if all viscosity values
measured at tem-
peratures between 20 �C and 100 �C (68 �F and 212 �F) or determined by
ex-
trapolation are within the range valid for this viscosity class. See
the viscosity
characteristics in the graph, Fig 2. Viscosity index improvers are not
permitted
because long-chain paraffins can cause clogging of the filter.
4)
The pour point has to be at least 10 �C below the lowest ambient
temperature in
winter, or a heater is required. An oil with a lower pour point, which
is possibly not
mentioned in the list of approved oils, can be used for special
applications.
5)
There is no sufficiently reliable correlation between demulsibility
according to DIN
51589 and water separability according to ISO 6614 or ASTM D 1401. It
depends
on the national regulations of the country where the oil is used which
of the two
criteria has to be fulfilled.
6)
If required, a provisional ageing test can be made (Total Oxidation
Products as
per ISO 7624; IP280). Requirements: Increase in acid number: max.
1.8mgKOH/g. Sludge content < 0.4%. It is possible that a product does
not pass
the quick test but the subsequent 2'000h TOST test.
7)
The limit value for new oil is not defined. The measurement is
important as a ref-
erence value.
8)
For turbines with gear an FZG fail level of at least 8 is required
(mineral oils with
EP additives). The gear manufacturer may require other FZG fail levels
for indi-
vidual plants.
9)
Equivalent test methods, for example DIN, NF, IP and BS methods can
also be
used.
1818 HTGD 693 000 V0140 A

en
MAV/MAX - HTGD090117V0001W - Lubricating
and Control Oils
Comparison
Fig. 2 Viscosity characteristics
en HTGD 693 000 V0140 A 1819

WP4140
3 SUPERVISION
Periodic supervision of the lube oil condition permits assessment
of the proper func-
tioning of the system and early action in the case of
malfunctioning.
Fig. 3 specifies the recommended periodic checks, standard values
and corrective
actions.
Test Method Frequency Spec. Value

Limit value Action
Appearance, see Visual Clear, light-yellow or

Cloudiness, dark Analyse in labora-
chapter 3.2 inspection coloured liquid
discolouration tory
Water content in oil Visual Once a

Cloudiness
month Clear liquid
Drain (centrifuge)
sample inspection
(no free water)
1)
Solid SAE AS4059 Class 7
Class 8 Filter.
1)
impurities ISO 4406 Class --/16/13
Class --/17/14 Replace filter
Level I 93%
Level I 80 %
Filterability ISO 13357-2
New filling
Level II 85 %
Level II 20 %
Water content
ASTM D 4928
according to 100 mg/kg
500 mg/kg Drain
ISO 12937
Karl Fischer
Check RPVOT
ASTM D664/ D974 According to original
Max. 0.2 mg KOH/g
Acid number
Contact oil
ISO 6618 condition analysis
above orig. value
supplier
ASTM D 445 According to

Exceeding E.g. check refill oil.
Viscosity
ISO 3104 ISO VG-class
ISO VG Find out reason
ISO 9120 4 min.ISO VG32/46

8 min. ISO VG32/46 Contact oil
Air release at 50�C
ASTM D 3427 7 min. ISO VG68
10 min. ISO VG68 supplier
Once a year
ASTM D 1401
Find out reason.
Water separability Max. 30 min.
Max. 30 min.
ISO 6614
Observe carefully.
New filling in the
case of poor oxida-

Demulsibility after
DIN 51589 Max. 300 seconds
Max. 360 seconds tion stability
steam treatment
Exceeding
Observe carefully
Copper content
15 - 25 ppm
Optional < 10 ppm
(solved in oil)
In worst case:
> 30 ppm
new filling
Oxidationinhibitor- ASTM D 2272/

content ASTM D 2668/ 25% of initial
25% from initial Contact oil supplier.
RPVOT/FTIR/ ASTM D 6810/ value
value Possibly new filling
Voltammetrie ASTM D 6971
1)
For control oil SAE AS4059 class 7, ISO 4406 class --/16/13
Fig. 3 Supervision
1820 HTGD 693 000 V0140 A
en
Lubricating
and
Control Oils
for Gas and Steam
Turbines
Specification and
supervision
3.1 Sampling
Take the oil samples for the monthly check of appearance and water content
from
the lower third of the oil tank.
Note
Take the oil sample from the pressure line downstream of the filter for the
quantita-
tive determination of impurities or for the annual check of the overall
condition !
The oil system must have been in operation for at least 12 hours before
taking the
sample!
Prior to the actual sampling (approx. 1 litre) discharge approx. 3 to 4
litres of oil (2 to
3 litres for all tests according to Fig. 3) for flushing the valves. Rinse
the clean sam-
ple receptacle three times with oil.
The valve must not be closed between flushing and sampling. After taking the
sam-
ple, close off tightly the sample receptacle. If the test is not carried out
in the plant's
own laboratory, the receptacle must bear the following information:
� Plant name
� Oil brand
� Sampling point
� Date and operating hours of oil filling
� Quantity refilled since last oil analysis
� Total refill quantity since oil filling
3.2 Explanatory notes on the tables

Appearance
When checking an approx. 10 cm thick oil film in transilluminating light, the
oil shall
be clear and free of visible foreign matter after settling down for 10
minutes.
Solid impurities
The solid impurities are classified in the following purity classes in
accordance with
their number and size per volume unit.
en HTGD 693 000 V0140 A

1821
WP4140
ISO 4406 (excerpt from ISO standard)

Number of particles per 100
millilitre
Class > 6 m
> 14 m
more than up to and incl. more
than up to and incl.
--/20/17 500'000 1'000'000
64'000 130'000
--/19/16 250'000 500'000
32'000 64'000
--/18/15 130'000 250'000
16'000 32'000
--/17/14 64'000 130'000 8'000
16'000
--/16/13 32'000 64'000 4'000
8'000
--/15/12 16'000 32'000
12'000 4'000
--/14/11 8'000 16'000 1'000
2'000
--/13/10 4'000 8'000 500
1'000
Fig. 4 Purity classes as per ISO 4406
Purity classes as per SAE AS4059

(replacing purity classes SAE 749 and NAS 1638)
Purity classes for different measuring methods (particles/100 ml)
SAE AS4059
1)
5 to 15m 15 to 25m 25 to 50m 50 to
100m > 100m
Class 2)
6 to 14m (c) 14 to 21m (c) 21 to 38m (c) 38 to
70m (c) > 70m (c)
3 2'000 356 63
11 2
4 4'000 712 126
22 4
5 8'000 1'425 253
45 8
6 16'000 2'850 506
90 16
7 32'000 5'700 1'012
180 32
8 64'000 11'400 2'025
360 64
9 128'000 22'800 4'050
720 128
10 256'000 45'600 8'100
1'440 256
11 512'000 91'000 16'200
2'880 512
Fig. 5 Purity classes as per SAE AS4059
1)
Size range, optical microscope based on longest dimension as
measured per
ARP598 or APC calibrated per ISO 4402: 1991
2)
Size range, APC calibrated per ISO 11171 for electron
microscope, based on
projected area equivalent diameter
1822 HTGD 693 000 V0140 A

en
Lubricating
and Control
Oils
for Gas and Steam
Turbines
Specification and
supervision
Note
Solid particles larger than 150 microns are not permitted!
If the lube oil is also used as control oil, it must have a purity per SAE
AS4059
class 7 or ISO 4406 class --/16/13!
4 REFILLING THE OIL TANK

The lube oil tank shall principally be refilled with oil of the same brand
and viscosity
class.
If a definite lube oil is no longer available on the market, it is
recommended to con-
sult the oil supplier to ensure a suitable replacement oil is filled in.
Refill the clean lube oil system always via a filter having a mesh size of 10
m in or-
der to filter out impurities.
Note
Mixing of different oils may cause accelerated ageing and precipitation of
additives!
Mixing of oils is only permitted after consulting the turbine and oil
suppliers.
The oil supplier has also to be consulted if other measures are required,
such as re-
inhibiting the oil. Such action is, however, only useful if previously tested
successfully
in the laboratory.
Note
It is recommended to record all refillings in order to permit changes in the
oil to be
correctly assessed.
5 SELECTION OF THE OIL SUPPLIER

Principally only mineral oils are permitted that meet the requirements of the
specifi-
cation table in Fig. 1.
5.1 Tested lube and control oils

The lube and control oils, tested and approved by ALSTOM on the basis of the
specification table in Fig. 1, are mentioned in Fig. 6.
Note
ALSTOM's approval does not exonerate the supplier from his responsibility
for the quality of his product.
The supplier must immediately inform ALSTOM if he changes the name of the
product, its composition or the name of his company.
Without being asked, the oil supplier has to confirm in writing every 5 years
that the
oils mentioned in the list still have the same composition and properties as
stated in
the table in chapter 2.5.
en HTGD 693 000 V0140 A

1823
With
EP addi-
Date of last tive
FZG extra
Brand name Designation
oil test req.
no
yes
ADDINOL Turbinen�l TL 46 May 1994 X
Turbine Oil 32 November 2004 X
ADNOC
Turbine Oil 46 November 2004 X
OTE 46 May 1992 X
AGIP OTE 32 GT January 2004
X
OTE 46 GT January 2004
X
Behran Oil Co. Turbine Oil 46 July 2003 X
Turbinol 46 January 1992 X
Turbinol X 32 October 1999 X
BP Turbinol X 46 October 1999 X
Turbinol X-EP 32 October 1999
X
Turbinol X-EP 46 October 1999
X
BP Lubricants North
BP Turbinol Select 32 November 2003 X
America
Regal Premium EP 32 August 1999
X
Caltex
Regal Premium EP 46 August 1999
X
Perfecto HPT46 May 1995
Perfecto AWT 46 March 2000
X
Perfecto XPT 32 October 1999 X
Castrol Heavy Duty
Perfecto XPT 46 October 1999 X
Lubricants
Perfecto XPG 32 October 1999
X
Perfecto XPG 46 October 1999
X
Turbine Oil 32 September 2002 X
Cepsa Turbinas EP 46 December 2000
X
GST Oil ISO 32 January1990 X
Chevron by a Chevron GST Oil ISO 46 March 2000 X
company Chevron GST 2300 ISO 32 February 2005
X
Chevron GST 2300 ISO 46 February 2005
X
Hydroclear Multipurpose R&O Oil 46 April 2000
X
Conoco Hydroclear Diamond Class � AW 32 November 2003
X
Hydroclear Diamond Class � AW 46 November 2003
X
1824 HTGD 693 000 V0140 A

en
Lubricating
and
Control Oils
for Gas and Steam
Turbines
Specification and
supervision
With EP addi-
Date of last
tive FZG extra
oil test
req.
no yes
Engen Petroleum
Engen Superturb 46 June 2004
X
Limited
Mobil DTE 732 February 2006
X
Mobil DTE 746 February 2006
X
DTE 832 March 2006
X
DTE 846 March 2006
X
ExxonMobil Mobil SHC 824 1) July 2003
X
Mobil SHC 825 1) July 2003
X
Teresstic T32 March 2007
X
Teresstic T46 March 2007
X
Teresstic GTC 32 November 2002
X
Fuchs Europe
Renolin Eterna 46 February 2009
X
Schmierstoffe GmbH
Gulf Oil International Gulf Crest EP 32 January 2009
X
Teresso GTC 32 September 2002
X
Imperial oil
Teresso GTC 46 September 2002
X
Servoprime 32G
Indian Oil Corporation August 2006
X
(Ciba additive Irgalube 2040A)
Remiz TG Super 46 August 2006
X
Lotos Oil SA Remiz TU 32 August 2007
X
Remiz TU 46 October 2007
X
Mol Hungarian MOL Turbine 32 K September 1997
X
Oil & Gas Co. MOL Turbine 46 K July 2005
X
Petrobras Lubrax Industrial Turbina EP 46 May 2002
X
KTL Turbine Oil 32 July 2006
X
Petrochina KTL Turbine Oil 46 July 2006
X
EP Gas Turbine Oil 32 July 2006
X
en HTGD 693 000 V0140 A

1825
WP4140
With EP addi-
Date of last
tive FZG extra
oil test
req.
no yes
Galp Turbinoil 32 August 1999
X
Petrogal
Galp Turbinoil 46 August 1999
X
PO Turbine Oil TX 32 July 2005
X
Petrol Ofisi
PO Turbina Oil TX 46 April 2006
X
Turbo Oil CC 32 (ISO VG 32) July 2007
X
Turbo Oil CC 46 (ISO VG 46) July 2007
X
Turbo Oil GT 32 (ISO VG 32) February 2008
X
Shell
Turbo Oil GT 46 (ISO VG 46) February 2008
X
Turbo Oil T 32 (ISO VG 32) February 2008
X
Turbo Oil T 46 (ISO VG 46) February 2008
X
Sinopec Great Wall Weiyue pre-
December 2004
X
mium turbine oil 32
Sinopec Great Wall Weiyue pre-
November 2008
X
mium turbine oil 46
Sinopec
Sinopec Great Wall Weiyue
February 2009
X
TSA/LF 46
Sinopec Great Wall Weiyue
February 2009
X
TSE/LF 46
Slovnaft (Manufac-
Madit TB 46 July 2005
X
tured by Mol-Lub Ltd.)
Regal EP 46 July 1995
X
Texaco Regal Premium EP32 August 1999
X
Regal Premium EP46 August 1999
X
Total Preslia GT 46 September 2007
X
1)
Basis: Synthetic hydrocarbon
Fig. 6 ALSTOM-tested lube and control oils as of April 2009
Most of the oils are also available as ISO VG 68.
1826 HTGD 693 000 V0140 A

en
Lubricating
and Control
Oils
for Gas and Steam
Turbines
Specification and
supervision
5.2 Untested lube and control oils

The following possibilities exist if a plant operator wants to use a mineral
oil that has
not been tested by ALSTOM:
� The oil is tested in ALSTOM's laboratory in accordance with the
specification ta-
ble in Fig. 1 and at the expense of the oil supplier. It is approved if all
require-
ments are met. The test requires approximately 4 months because of the
ageing
test (2'000 hours).
� If ALSTOM agrees, some tests can be carried out in certified laboratories.
en HTGD 693 000 V0140 A

1827
Blank Page
1828 HTGD 693 000 V0140 A en

Lubricating
and Control Oils

for Gas and
Steam Turbines
Specification
and supervision
6 CHECKLIST
Notes on the acceptance of and procedure for the delivery of oil or
hydraulic
medium to the plant and for the first filling of the lube oil or
hydraulic tank
Plant: ALSTOM order No.:
Customer/plant operator:
Medium supplier: Medium/type:

Viscosity:
ISO VG
Delivery: Tank cars

Barrels
Carrier: other
Date of delivery: Supplied quantity:
Does the supplied type agree with the ordered medium type?
Test certificate of the supplier must be available: Date:

Available yes no (chapter 2.3 of specification)
Sampling on delivery:
Before unloading or filling the lube oil/hydraulic tank, at least 3 samples of
approx. 2 litres each must be
taken from the supplied charge and forwarded to the chemical engineer of the
customer (to ensure sub-
sequent traceability). The samples must at least bear the following information in
a legible and durable
manner:
� Identification of supplier and product (type, viscosity class)
� Carrier, date of delivery, charge or delivery No.
� Name and order No. of turboset
Medium will be used for:

Brg. oil lubrication with hydraulic system Only brg. oil lubrication
Hydraulic system
Filling the tank:

When filling the tank for the first time, the medium must be passed through a
filter unit (e.g. oil centrifuge,
filter re-pumping unit or similar unit). Minimum requirement: 25 m filter cloth
over filling opening.
See also flushing instructions for the plant in question.
Date of filling: Filled-in quantity:
Filter unit used: Filter mesh:
Date: Initialled by ALSTOM

representative:
(Commissioning/Erection
Project Man.)
Checklist and test certificate of oil supplier (see above) forwarded to ALSTOM PM
on:
en HTGD 693 000 V0140 A

1829
WP4110 & WP4140
Remarks:
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HTGD090117V0001W
1830 HTGD 693 000 V0140 A

en
MAX11- HTGD690411V9000 -
MAX11- HTGD690411V9000 -
en HTGD 693 000 V0140 A 1831

Revision History
total :
- - (10)
1832 HTGD 693 000 V0140 A en

MAX11- HTGD690411V9000 -
Contents
1
PURPOSE............................................................................
............................................................1835
2
CONSTRUCTION ......................................................................
......................................................1836
3 PRINCIPLE OF
OPERATION .........................................................................
.................................1836
4 CAUSES OF MALFUNCTIONS AND CORRECTIVE
ACTIONS ....................................................1836
5 DISMANTLING AND RE-
ASSEMBLY ..........................................................................
...................1837
5.1
Dismantling .......................................................................
................................... 1837
5.2 Re-
assembly ..........................................................................
.............................. 1840
en HTGD 693 000 V0140 A

1833
WP4110 & WP4140
Figures
Fig. 1-1 General

view ..............................................................................
................................ 1835
Fig. 5-2 Sectional
view ..............................................................................
.............................. 1839
Test certificates
1834 HTGD 693 000 V0140 A

en
MAX11- HTGD690411V9000
-
Constant Pressure
Valve
1 PURPOSE
The constant pressure valve is a proportional controller which limits the
pressure of a
hydraulic medium admitted to its input side according to adjustment and valve
char-
acteristic.

1 Housing 8 Compression spring
2 Cover 9 Setscrew
3 Guide bushing 10 Compression spring
4 Main control piston (a) Control system
5 Bushing (b) Drain
6 Guide piece (c) Leakage
7 Pilot control piston (d) Leakage
Fig. 1-1 General view
en HTGD 693 000 V0140 A

1835
2 CONSTRUCTION
The constant pressure valve comprises the main control unit and the screwed-
on pi-
lot control unit.
The most important component of the main control unit is the main control
piston 4.
With operating pressure, the piston moves in the guide bushing 3 and the
bushing 5
against the force of the compression spring 10.
The pilot control unit consists mainly of the guide piece 6 in which the
pilot control
piston 7 counteracts the force of the compression spring 8. The spring is
preten-
sioned with the setscrew 9 in the cover 2, adjusting the desired value
within the con-
trol range indicated on its rating plate.
The pressure in system (a) which is to be controlled acts on the main
control piston.
The force of the compression spring 10 and the pilot control pressure in its
spring
chamber are in equilibrium. In accordance with the characteristic of a
proportional
controller, the controlled pressure is slightly dependent on the flow rate
between the
main control piston 4 and the bushing 5.
The pilot control pressure prevails in the chamber between the fixed orifice
(bore) in
the main control piston and the discharge area between the guide piece 6 and
the
pilot control piston 7. The pilot control pressure, regulated by this
discharge area,
acts on the pilot control piston against the balancing force of the
compression spring
8, i.e. a greater compression spring force corresponds to a higher pilot
control pres-
sure and, based on the force ratio at the main control piston, also to a
higher pres-
sure in the control system (a).
4 CAUSES OF MALFUNCTIONS AND CORRECTIVE ACTIONS

The following points describe malfunctions or oscillations in the control
system and
how to correct them.
� System line at connections (c), (d) not vented. Vent the lines and make
sure they
are laid with a steady rise.
� System pressure deviates from the setpoint value. Remove cap nut 11,
unscrew
nut 12, and use setscrew 9 to set precisely the setpoint pressure.
� Constant pressure valve does not respond to pressure changes. Remove main
valve piston 4, clean it and eleminate any friction marks on it and at the
guide
bushing 3 and bushing 5.
1836 HTGD 693 000 V0140 A
en
MAX11- HTGD690411V9000
-
Constant Pressure
Valve
5 DISMANTLING AND RE-ASSEMBLY

Under normal circumstances the constant pressure valve does not require
mainte-
nance.
WARNING
Pressure hazard
Do not lean or bend over pressurised equipment.
Dismantling is only permitted after the system has been
pressure-
relieved.
Make sure that persons not involved in the operation are
outside the
danger area.
Note
During dismantling, care must be taken to make sure that all parts
coming
into contact with pressure medium are absolutely clean.
5.1 Dismantling
Starting point
Remove the connecting lines and bolted joints from the tank and pressure
lines and
lift-off the constant pressure valve.
Note
Pay attention to escaping pressure medium. Make available an oil
pan.
� Remove the cap nut 11 according to Fig. 5-2 by loosening the hex. nut 12
and
setscrew 9.
Note
Prior to relieving the compression spring 8 record the operating
position of
the setscrew 9 to permit the same setting after re-assembly.
� Relieve the compression spring 8 as far as possible.
� Loosen uniformly the cover 2 until the compression spring 8 is completely
re-
lieved and lift it off.
� Remove spring plates and compression spring 8.
� Lift off guide piece 6.
en HTGD 693 000 V0140 A
1837
� Loosen uniformly the hex. head bolts 13 to relieve the compression spring
10 and
remove the flange 14.
� Pull the guide bushing 3 with main control piston 4 and compression spring
10 out
of the valve housing 1.
� Remove the bushing 5.
1838 HTGD 693 000 V0140 A

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MAX11- HTGD690411V9000 -
Constant Pressure
Valve

2 Cover 11 Cap nut
3 Guide bushing 12 Hexagon nut
4 Main control piston 13 Hexagon head bolt
5 Bushing 14 Flange
6 Guide piece 15 Gasket
7 Pilot control piston 16 Gasket
8 Compression spring 17 Seal
9 Setscrew
Fig. 5-2 Sectional view
en HTGD 693 000 V0140 A 1839

5.2 Re-assembly
Re-assemble in reverse order.
Install new gaskets 15 and 16 and seals 17.
Note
Clean thouroughly all parts coming into contact with pressure
medium
bevore re-assembling.
Adjust the setscrew 9 of the compression spring 8 according to the
record
measurement from the dismantling.
Tighten the hex. head bolts 13 and the bolted joints of the Document
pressure lines according to the values given in the data sheet. HTGD 630
147
Re-connect all connecting lines leak-tight.
HTGD690411V9000
1840 HTGD 693 000 V0140 A

en
MAX43 - HTGD690743V0001A -
Trip Unit 2-out-of-3 relay
MAX43 - HTGD690743V0001A -
en HTGD 693 000 V0140 A 1841

Revision History
total :
A New content, 98-04-27 -
- - (6)
1842 HTGD 693 000 V0140 A en

MAX43 - HTGD690743V0001A -
Contents
1
PURPOSE............................................................................
............................................................1845
2
CONSTRUCTION ......................................................................
......................................................1846
3 PRINCIPLE OF
OPERATION .........................................................................
.................................1846
en HTGD 693 000 V0140 A

1843
WP4110 & WP4140
Figures
Fig. 1 Trip
unit...............................................................................
........................................... 1845
Ttest certificates
Sequence valve
1844 HTGD 693 000 V0140 A

en
MAX43 - HTGD690743V0001A
-
Trip Unit 2-out-
of-3 relay
1 PURPOSE
The 2-out-of-3 relay trip unit, shown in Fig. 1, connects the eletronic and
the hydrau-
lic safety system. It converts the electric trip signals into hydraulic
signals and com-
bines them to a 2-out-of-3 selection.

1 Housing 5 Trip solenoid valve,
channel 3
2 Main control slide valve 6 Ball valve
3 Trip solenoid valve, channel 1 7 Check valve
4 Trip solenoid valve, channel 2 8 Compression spring
Fig. 1 Trip unit
en HTGD 693 000 V0140 A

1845
2 CONSTRUCTION
The trip signals are transmitted to the trip solenoid valves 3 to 5,
channels 1 to 3,
which operate according to the normally energized circuit principle. The 3
ball valves
6 which are connected ahead of each solenoid valve permit separation of the
sole-
noid valves from the hydraulic system and can be replaced during operation
if defec-
tive. The required safety is then ensured by a 1-out-of-2 selection.
The 3 main control slide valves 2 are a combination of slide and seat
valves. They
are moved into the fail-safe position under spring force 8 in case of a
turbine trip or
component failure.
As the position of the main control slide valves is visible from outside,
their proper
functioning can be tested locally by the ball valves 6.
Rated values for functional tests are given in the test Test
certificate
certificate. HTGD 479
469
The 2-out-of-3 logic is realized in the hydraulic part. The pressure in the
emergency
system is only discharged if at least two solenoid valves are de-energized
because
the connection to the drain is always via at least two main control slide
valves.
The pressure in the test system decreases if a defect occurs in the trip
circuit or if
one of the solenoid valves is de-energized. This pressure is used as
feedback when
testing a channel.
If the solenoid valves are energized, the pressure oil pressure is admitted
via orifices
to the piston of the main control slide valves 2. The main control slide
valves move
towards the valve seats in the housing 1 and close the connection to the
drain.
If the solenoid valves are de-energized, the compression spring 8 forces the
main
control slide valve into the fail-safe position and the medium is passed to
the tank via
the drain.
HTGD690743V0001A
1846 HTGD 693 000 V0140 A

en
MAX43 - HTGD690744V0001C -
Sequence Valve
MAX43 - HTGD690744V0001C -
Sequence Valve
en HTGD 693 000 V0140 A 1847

Revision History
Document Pages
total :
A New content, 98-04-21
8
B Page 3: "Mech.overspeed trip and Emergency trip unit" deleted. (op-
8
tions) 01-11-21
C Page 6: "Text change in chapter 2.2 Reset and filling of the pipe sys-
8
tem" - 05-12-20
- -
(8)
1848 HTGD 693 000 V0140 A

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MAX43 - HTGD690744V0001C -
Sequence Valve
Contents
1
PURPOSE............................................................................
............................................................1851
OPERATION ...................................................................1851
2.1
Tripping ..........................................................................
...................................... 1852
2.2 Reset and filling of the pipe
system ..................................................................... 1852
2.3 Normal
operation .........................................................................
........................ 1852
2.4 Testing of a trip
channel............................................................................
........... 1854
2.5 Discharge
amplifier .........................................................................
..................... 1854
en HTGD 693 000 V0140 A

1849
WP4110 & WP4140
Figures
Fig. 1 Sequence
valve .............................................................................
................................ 1853
Test certificates MAX
Trip unit
1850 HTGD 693 000 V0140 A

en
MAX43 -
HTGD690744V0001C -
Sequence
Valve
1 PURPOSE
The sequence valve, shown in Fig. 1, permits the use of a dual-pipe hydraulic
sys-
tem, i.e. the safety system is also the hydraulic supply system. As only two
pipe
lines, hydraulic supply and drain, are required for the entire safety and
control sys-
tem the piping can be considerably reduced. The sequence valve is controlled
by the
trip unit, 2-out-of-3-relay, or aditionally an optionally available mechanical
trip device,
for example a mechanical overspeed trip.

The sequence valve consists of a control slide valve 5 which can assume 4
positions
and a plate-valve-type discharge amplifier 4, connected in series.
The 4 positions of the control slide valve are:
� turbine trip
� reset and filling of the pipe system
� normal turbine operation
� test of a trip channel
The position "normal turbine operation" is monitored by a proximity sensor 6.
The
signal of this sensor is also the feedback signal of a successful test of a
trip channel.
The control slide valve positions "turbine trip" and "normal operation" are
indicated
by a mechanical pin. The switching state of the control slide valve can
therefore be
checked externally in case of disturbances.
The control slide valve controls the flow of the hydraulic pressure medium
from the
pumps to the supply system of the control valve actuators and the drain from
this
supply system by means of one main control edge each. In case of a trip the
se-
quence valve prevents the start of the redundant hydraulic pump by blocking
the
supply system which is pressure-relieved via the discharge amplifier.
In the event of a trip the discharge amplifier opens a large discharge cross-
section,
depressurizing the supply system. This cross-section is so dimensioned that
the
supply system can be properly depressurized even if the control slide valve
fails. A
failure of the discharge amplifier is not possible because of its design. The
function-
ing of the control slide valve is therefore not safety-relevant.
en HTGD 693 000 V0140 A
1851
2.1 Tripping
In the tripped condition an increase of the pressure exerted on the piston
surface of
the control slide valve 5 is impossible because the drain is open via the
check valve
7 and the control slide valve of the trip unit. The control slide valve is
pressed against
a stop by the compression spring 8. The discharge amplifier 4 is open and
dis-
charges the safety system into the drain. The flow from the pumps to the
safety sys-
tem is interrupted by the main control edge of the control slide valve.
2.2 Reset and filling of the pipe system

In case of a reset the drain is closed by the control slide valve. The
pressure in the
emergency system is increased. The discharge amplifier 4 closes.
The pressure downstream of the orifice 9 increases because the check valve
10 is
blocked by the pressure in the emergency system. The control slide valve is
moved
against the spring so far that the main control edge engages with a
throttling slot.
As long as the pipe system is not entirely filled an increase of the
pressure on the
piston surface of the control slide valve is not possible because the
hydraulic me-
dium flows immediately via the check valve 10 into the safety system. Due to
the
throttling at the control edge the pipe system is filled up slowly,
preventing a pres-
sure surge. As soon as the pressure in the pipe system exceeds a limit value
the
control slide valve moves into the operating position.
2.3 Normal operation

During normal operation the control slide valve 5 is in its outermost right
position.
The flow from the pumps to the safety system via the main control edge of
the con-
trol slide valve is unrestricted.
1852 HTGD 693 000 V0140 A

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MAX43 - HTGD690744V0001C -
Sequence
Valve

1 Trip unit 7 Check valve
3 Amplifier housing 9 Orifice
4 Discharge amplifier 10 Check valve
5 Control slide valve 11 Bypass orifice
6 Proximity sensor
Fig. 1 Sequence valve
en HTGD 693 000 V0140 A 1853

2.4 Testing of a trip channel

When testing a trip channel, one solenoid valve of the trip unit, 2-out-of-3
relay, is
de-energized, depressurizing the test system. The pressure on the piston
surface of
the control slide valve 5 decreases, i.e. the control slide valve moves
until its control
edge engages, interrupting the discharge to the test system.
The control slide valve performs a partial stroke which is monitored by the
proximity
sensor 6. The signal of the sensor is the feedback signal of a successful
test of a trip
channel.
Rated values for functional tests are given in the test Test
certificate
certificate. HTGD 479
470
2.5 Discharge amplifier

The valve is pressurized on the spring side by the emergency system and on
the op-
posite side by the safety system. The emergency system can be depressurized
by
the trip unit, 2-out-of-3 relay, and an optional mechanical overspeed trip.
The dis-
charge amplifier 4 is opened by the pressure of the safety system which can
be
drained directly into the tank of the pressure generation.
HTGD690744V0001C
1854 HTGD 693 000 V0140 A

en
MA - HTGD691892V9000 -
Decommissioning & Disposal Guideline for ALSTOM
Steam Turbines
MA - HTGD691892V9000 -
Decommissioning & Disposal
Guideline for ALSTOM
Steam Turbines
en HTGD 693 000 V0140 A 1855

Revision History
Revision Date Contents
- - (42)
Table 1 Revisions
1856 HTGD 693 000 V0140 A en

MA - HTGD691892V9000 -
Decommissioning
& Disposal Guideline for ALSTOM
Steam Turbines
Contents
1
INTRODUCTION.......................................................................
.......................................................1864
1.1
General ...........................................................................
..................................... 1864
1.2 Definitions and
abbreviations......................................................................
......... 1866
2 SAFETY
INSTRUCTIONS ......................................................................
.........................................1867
2.1 Legal
requirements ......................................................................
........................ 1867
2.2 Safety
precautions .......................................................................
........................ 1868
2.3 Standard engineering
practices .........................................................................
.. 1869
2.4 Hazard
sources............................................................................
........................ 1869
2.4.1 Tools and lifting
devices ..........................................................................
1870
2.5 Hazard symbols - hazard
nomenclature .............................................................. 1870
3 DECOMMISSIONING AND
DISMANTLING........................................................................
............1871
3.1 Phases
overview...........................................................................
....................... 1871
3.2 Decommissioning
planning ..........................................................................
........ 1871
3.2.1 Environmental
assessment .....................................................................
1872
3.3
Execution .........................................................................
.................................... 1876
3.3.1 Health and safety during decommissioning and
deconstruction ............. 1876
3.3.2 Decommissioning
procedures ................................................................. 1877
3.4
Documentation......................................................................
............................... 1883
4
DISPOSAL ..........................................................................
.............................................................1884
4.1 Residual material and waste

management.......................................................... 1884
4.1.1 Waste sorting and
segregation................................................................ 1885
4.2 Disposal-relevant
components.........................................................................
.... 1887
4.3 General
refuse ............................................................................
......................... 1887
4.4 Chemical
waste..............................................................................
...................... 1888
4.5 Handling and disposal of hazardous materials on decommissioning
sites .......... 1888
4.5.1
Introduction.......................................................................
....................... 1888
4.5.2 General guidelines for handling & disposal of hazardous
materials........ 1889
4.5.3 Handling fibrous
materials.......................................................................
1890
4.5.4 Handling
poisons............................................................................
......... 1890
4.5.5 Handling acids,
lyes ..............................................................................
.. 1892
en HTGD 693 000 V0140 A

1857
WP4110 & WP4140
4.5.6 Handling solvents and products containing solvents and

products
containing
solvents" .........................................................................
....... 1892
4.5.7 Handling two-component resins (paints, varnishes,
resins).................... 1894
4.5.8 Handling oils, lubricants, oily
emulsions.................................................. 1894
4.6 Storage of reusable
components.........................................................................
1895
4.7 Return to the
manufacturer.......................................................................
........... 1895
4.8 Material Safety Data
Sheets ............................................................................
.... 1895
Figures
Fig. 3-1 General

arrangement .......................................................................
.......................... 1879
Fig. 3-2 Decommissioning
sequence ..........................................................................
............ 1882
Tables
Table 1
Revisions .........................................................................
........................................... 1856
Table 2 Manual
elements ..........................................................................
.............................. 1860
Table 3
Regulations........................................................................
......................................... 1861
Table 4 Definitions and
abbreviations .....................................................................
................ 1866
Table 5 Material to be disposed
of ................................................................................
.......... 1880
Table 6 Waste stream
types..............................................................................
...................... 1886
Table 7 Waste stream
types..............................................................................
...................... 1887
1858 HTGD 693 000 V0140 A

en
MA - HTGD691892V9000 -
Decommissioning & Disposal Guideline for
ALSTOM
Steam
Turbines
Important notes
All rights reserved
� Copyright 2006 ALSTOM (Switzerland) Ltd.
CH-5401 Baden, Brown Boveri Strasse 7
Preparation by ST Packaging Documentation
Printed in Switzerland
This work, including all parts thereof, is protected by copyright. Any use of
it beyond
the narrow restrictions of the copyright law without prior approval of ALSTOM
(Swit-
zerland) Ltd., CH-5401 Baden, is prohibited and subject to punishment under
the
applicable law.
The above pertains in particular to reproduction, translation, microfilming,
and elec-
tronic data processing.
Please direct any inputs regarding the contents of this manual to the
responsible
documentation manager at the mail address below:
st.packaging.documentation@power.alstom.com
en HTGD 693 000 V0140 A

1859
About this Manual

Scope of this manual
This manual contains essential information for
� Safe decommissioning
� Environment-friendly and safety-conform disposal
� Recycling and reconditioning of installations, material etc.
Disposal becomes necessary during
� Operation, for further operation-specific disposal procedures refer to the
operation
manual
� Maintenance, for further maintenance-specific disposal procedures refer to
the
maintenance manual
� End of life (described in this manual) of the installations.
Target Audience
This manual is written for everyone working on or with the fossil fired
steam turbine.
It conveys information for different user audiences to understand and fulfil
their work
and duties.
How to use this manual
There are several features that will help up find specific information
quickly:
Manual element ... is found at...

Table of contents beginning of book
General index end of book
List of figures, list of ta- beginning of book
bles
Margin column throughout the book, contains explanations
or headlines for
navigation purposes
Table 2 Manual elements
This manual is also available as PDF-file. For a quick search, use the PDF
search
function.
1860 HTGD 693 000 V0140 A

en
MA - HTGD691892V9000 -
ALSTOM
Steam
Turbines
Note
This document is the art of technique at 2007. It is a "live" document that
requires
updating during the stage of the unit to be decommissioned, and there will be
more
know how, information, techniques available in that stage.
The manual is a notebook. Feel free to write your own notes, ideas, questions,
in-
dices, glossary items, etc. into this manual.
Regulations
Regulation Content
2006/42/EG Machine directive
ISO 14123 Disposal guideline
2002/96EG Disposal of electrical and electronic components
EN 1050 Safety of machinery, principle of risk assessment
Table 3 Regulations
en HTGD 693 000 V0140 A

1861
Safety instructions in the Manual

complied with
document.
Warning,
Caution, Note and Parts List Reference. These symbols are used in the
following cir-
cumstances:
DANGER
Type/Source of Hazard
Consequence of the hazard
Action(s) to avoid the hazard.
DANGER indicates an imminently hazardous situation which, if not avoided,
will re-
sult in death or serious injury. This signal word is limited to the most
extreme situa-
tions.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided,
could
result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided,
may re-
sult in minor or moderate injury. This note is also used to alert against
unsafe prac-
tices.
1862 HTGD 693 000 V0140 A

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MA -
HTGD691892V9000 -
Steam Turbines
Other Symbols and Notes

Note
In addition to the safety instructions shown below, the manual
contains general in-
formation notes.
Note
This note points out mandatory actions that do not impair safety,
but are absolutely
necessary to perform a procedure as described.
Caution
This is the standard note pointing out possible damage to material.
This is not a
safety instruction and is not used as such.
For example: "Remove all tools from the motor before starting it.
The gearbox could
be damaged."
12
3 It is mandatory to read the specific instructions contained in this
manual or external
reference documents.
Special In some cases the disposal or decommissioning tasks require the use
of special
tools
tools and lifting devices. Where such tools and lifting devices are
required, their use
is detailed in the relevant text and marked both in text and on the
appropriate figure
by the symbol .
en HTGD 693 000 V0140 A

1863
1 INTRODUCTION
1.1 General
Legal notice Neither ALSTOM nor any person acting on ALSTOM's behalf either
a) makes any warranty, express or implied, with respect to the use
of any informa-
tion or methods disclosed in this document or
b) assumes any liability with respect to the use of or reliance on
information or
methods disclosed in document
Any recipient of the document, by acceptance of, reliance on, or use
of methods, re-
leases and discharges ALSTOM from liability. Release and discharge
annul all liabil-
ity for any direct, indirect, consequential or special loss or
damage. Release and dis-
charge are independent of whether such loss or damage arises in
contract, strict li-
ability, tort (including the negligence of ALSTOM in the preparation
of estimates), or
otherwise
Information furnished by ALSTOM hereunder shall not be used or
referred to in con-
nection with the offering of securities or other public offering.
Opening ALSTOM as OEM cannot regulate the decommissioning of its products.
However,
notice
this document gives guidelines for safe and environmental correct
decommissioning
and disposal.
Note
There will be more know how, information, techniques during the
process of
plant/unit decommissioned which are not specified in this manual.
There are companies, which are specialized for decommissioning work.
The owner of the plant in which ALSTOM equipment is operated is
responsible for
compliance with local legal and statutory safety and environmental
requirements. All
guidelines given here are based on the "as delivered" status of the
equipment.
The guidelines given in this document may be useful for the owner
� To prepare and review decommissioning plans
� For conducting inspections
� For monitoring the status of activities, to assure that
environmental contamination
is minimized and compliance with the legal and statutory
requirements is en-
sured. This monitoring system shall ensure that safety and
environmental re-
quirements are met throughout the process
The goals of the survey program at sites undergoing decommissioning
are to:
1864 HTGD 693 000 V0140 A
en
MA - HTGD691892V9000 -
ALSTOM
Steam
Turbines
� Ensure, through the review and approval of decommissioning plans and

surveys,
that the decommissioning can be conducted safely and in accordance with
local
regulations and requirements
� Ensure, through direct observation and verification, that the
decommissioning is
being conducted in accordance with the approved decommissioning plan and lo-
cal regulations
� Ensure that corrective actions are taken on facilities undergoing
decommissioning
if they are not conforming to the approved decommissioning plan or local
regula-
tions
Inspection reports, correspondence, and other information about facilities
undergoing
decommissioning shall be kept, to provide evidence for safe and environmental
sound decommissioning.
en HTGD 693 000 V0140 A

1865
1.2 Definitions and abbreviations

Term Explanation
Installation Collective term for power plants, Steam
Turbine Package
means steam turbine and all auxiliary
systems, but does not
mean any buildings or supportive
constructions, external pip-
ing and other installations.
Decommissioning All measures following the final termination
of operation of a
installation. This includes the aim to
achieve a provisional
safe enclosure or finally the complete
dismantling of the in-
stallation. Actions taken at the end of the
life of an installation
to retire it from service with adequate
regard for worker's
health and safety, the public's overall
safety, and protection
of the environment. These actions include
surveillance and
maintenance, characterization and
dismantling or demolition.
Dismantling encompasses the disassembly or
demolition and
removal of any structure, system, or
component during de-
commissioning and satisfactory disposal of
the residue from
all or portions of a installation.
Phases of a plant's life � planning
� construction
� commissioning
� operation
� post-operation
� decommissioning (including preparation for
safe disman-
tling, the dismantling and the material
management)
A power plant or the equipment that has been
permanently
shut down and from which the steam supply
and the interface
to public power lines has been safely
removed will be trans-
ferred into a state of readiness for safe
dismantling.
Ready for safe dismantling status of the
equipment: all pos-
sible energy sources are locked, controlled
and in safe condi-
tions. All possible hazards for environment
are locked, con-
trolled and in safe conditions.
Disposal Disposing of decommissioned material in an
environmental
safe way; recycle, recondition, reuse or
deposit the different
materials
MSDS Material Safety Data Sheet; all chemical
material will be ex-
plained in case of composition, hazards
identification, first-aid
and fire fighting measures, toxicological
info etc.
Table 4 Definitions and abbreviations
1866 HTGD 693 000 V0140 A

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MA -
HTGD691892V9000 -
Steam Turbines
2 SAFETY INSTRUCTIONS
2.1 Legal requirements
The decommissioning of an installation may be regulated. In
addition to the national
laws and regulations, the following guidelines must be considered:
� sound engineering practices and recommendations
� recommendations and publications of other international
committees
Regulations affecting decommissioning may fall into three
categories:
� Those that directly affect decommissioning e. g. the approval of
any decommis-
sioning operations
� Those that protect the worker and the public during
decommissioning operations
� Those that apply if hazardous or toxic materials are present in
the installation
The factors critical to a successful, on time completion of
decommissioning activities
are:
� sound planning for communication with the regulatory agencies
� compliance with the regulatory requirements
These factors are an integral part of the initial planning
activities.
Documenta- Documenting the decommissioning of an installation decommissioning
is most im-
tion is a key
factor portant. For the performing company, documentation bring by
evidence of the correct
decommissioning of the installation. It also demonstrates that
proper decommission-
ing has actually been performed.
The closure or decommissioning report should include
� A summary of installation operations
� Descriptions of hazardous materials used
� An inventory of hazardous waste generated
� Identification of known releases
� Chemical inventory lists and data from Material Safety Data
Sheets used, to es-
tablish a chemical analysis plan.
� A pre-closure inspection must be documented with photographs to
develop and
justify post-decontamination sampling locations. The report must
include
- Photographs of contractor activities - equipment removal
- Decontamination/milling and sampling
- Copies of daily work logs
- Hazardous waste manifests, and laboratory reports
en HTGD 693 000 V0140 A
1867
- Notices of permit termination and a summary of a post closure final

inspec-
tion with photographs
Wipe and chip samples may indicate that residual contamination on/in
building sur-
faces remains. The risk posed by residual contaminants should be evaluated.
2.2 Safety precautions

The following general safety precautions apply to all procedures related
end-of-life
cycle tasks (disposal and decommissioning). Throughout the text, where
applicable,
specific warnings are inserted prior to the related procedural step.
Note
All personnel working in the decommissioning process must comply with the
lo-
cal/regional safety requirements.
Safe status
� Prior to starting any disposal or decommissioning work, ensure that the
steam
turbine and all interfacing systems are shut down, drained and made safe
as de-
tailed in the Operation Manual
� Permanently shut down and from which the steam supply and the interface to
public power lines has been safely removed will be transferred into a
state of
readiness for safe dismantling.
� Ready for safe dismantling status of the equipment: all possible energy
sources
are locked, controlled and in safe conditions. All possible hazards for
environment
are locked, controlled and in safe conditions.
� When handling thermal insulation mats, always wear personal protective
equip-
ment including at least eye protection, approved face masks and gloves
� When using cleaning solvents, always wear person protective equipment, ap-
proved protective goggles, gloves and clothing
� When operating welding equipment or grinding machines, always wear
approved
procedures
are observed and all personnel not involved in these operations are clear
of the
immediate area
� When using the special hydraulically operated tools, ensure that the
manufac-
turer's recommendations are followed. Do not lean over the tool when
pressure is
applied
� Use only the approved lifting devices and operate them in accordance with
the
� Make sure that the load is correctly secured
� Never stand on or under a suspended load
1868 HTGD 693 000 V0140 A
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� Make sure that all personnel not involved in the lifting operation are kept
clear of
the immediate area
2.3 Standard engineering practices

If you intend to reuse some specific items like blades, components, etc. you
need
specific definitions and procedures like:
� What shall be reconditioned and how?
� How can the components be decommissioned without material damage?
� Etc.
Follow the standard engineering practices described in the following
paragraphs dur-
ing all decommissioning or disposal processes. Knowledge of, and the correct
use
of, tools and equipment is assumed throughout.
2.4 Hazard sources

Hazard sources need appropriate safety measures to control the risk. Any
measure
should be based on a professional risk assessment. Typically the risk
assessment
should cover:
� Heavy machining
� Chemical, thermal, electrical, mechanical dangers
� Traffic
� Noise
� Fire and explosion hazards, like naked flames
� Work with welding and grinding equipment
� Scaffolding
� Pressurized and not purged systems, components, pipes etc.
� Break up of repositories under pressure
� Open dumps, ejected parts
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2.4.1 Tools and lifting devices

In some cases the disposal or decommissioning tasks require the use of
special
tools and lifting devices. The text and figures which detail the use of
these tools are
marked by a square symbol .
After each stage of dismantling, unless stated otherwise, return these
tools to their
tool chests:
� jacking screws
� guide bolts
� taper pins and approved maintenance covers
Be sure that the tools are clean before they are properly stored.
Note
Any exceptions to the above statement are detailed in the procedural text.
dam-
2.5 Hazard symbols - hazard nomenclature

The following table shows the hazard symbols used on material bins,
containers,
etc.:
Flammable and combustible Highly toxic
material
Highly flammable Corrosive
Explosive Irritant
Oxidizing agent Harmful
Toxic Dangerous for

environment
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3 DECOMMISSIONING AND DISMANTLING

3.1 Phases overview
� Planning, see chapter 3-2
� Execution, see chapter 3-3
� Documentation, see chapter 3-4
3.2 Decommissioning planning

Assessment The first phase of planning a decommissioning project must include
initial investiga-
tion and assessment. In this project phase you plan and define
� Current conditions
� Regulatory requirements
� Areas of concern
� Alternatives for future action
The initial investigation is very important because the future
technical and financial
project decisions will be based on its results.
Risk Elimination or reduction of risk to acceptable limits is a primary

goal of the decom-
elimination missioning planning. These risks/liabilities include potential
impacts on human
health, both workers and the public, and the environment. See also
the related regu-
lations e.g. EN 1050, etc.
Risk reduction Data is needed to evaluate risks, potential strategies to reduce
risks, and the associ-
ated costs and benefits associated with each strategy. Decision
makers must be
able to:
� Identify incremental risk reductions
� Evaluate various approaches/combinations
� Consider impacts of perceived risk reductions
� Estimate costs for each incremental reduction
� Evaluate benefit versus cost and timing of these benefits
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3.2.1 Environmental assessment

An environmental assessment must identify and determine the nature
and extent of
any hazardous materials or environmental contaminants at the
facility. There are
methods to help make this efficient and effective. ALSTOM's
recommended ap-
proach is to use existing information to direct the environmental
investigation efforts
rather than starting out with a widespread sampling program.
The environmental sampling activities then can be directed toward the
potential
sources of concern and include the known or suspected materials of
concern. This
focused approach reduces sampling effort, laboratory analysis and
associated costs.
Information Available information sources should be reviewed as the first step of
the environ-
collection
mental assessment. Potential information sources, helpful to direct
subsequent
phases of the environmental assessment include:
� Current site conditions based on observations
� Process knowledge and operational reports
� Information regarding past maintenance practices
� As-built or as-maintained drawings
� Previous environmental investigation and management reports
� Regulatory agency inspections, reports and files
� Accident reports and environmental incident reports
� List of disposal collecting places for different materials like
oil, batteries, etc.
These sources can often provide valuable information about prior
activities at a facil-
ity. Process knowledge and prior operational reports should describe
the types of ac-
tivities performed during the life of the facility. This information
in turn can provide
valuable insights about the potential types of environmental issues
that may have
been associated with those processes.
Example � Operational reports may also give information about process upsets,
chemical
storage, spillage, and any former abatement activities.
� Building age and type of construction can provide insight into the
likelihood of en-
countering metal-based coatings. Past maintenance practices can
provide insight
into historical activities that may have impacted building
materials or environ-
mental media at the facility.
� Historical aerial photographs that include the facility in question
are often avail-
able. These photographs have proven to be valuable in confirming
the recollec-
tion of facility staff or providing a catalyst for stimulating
their recall. Aerial photo-
graphs also can be very useful for identifying outdoor storage
areas, spillage, and
operations that are no longer current. At military installations,
facilities which were
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considered sensitive at a given time sometimes have been blocked

out from pho-
tographs of the surrounding area.
� Regulatory agency files can also be a source of historical
information. Previous
inspections, spillage notifications, and operations reports
contained in these files
can provide insight into historical operations and potential
environmental con-
cerns.
Environmental Sampling should be performed to define the full nature and extent
of materials, if
sampling
based on the results of information collection - known or suspected
hazardous build-
ing materials or environmental constituents of concern are believed
to be present.
This environmental sampling process must be directed by the
information collected
about the historical operations and process knowledge. This is
especially valid for
large facilities where investigation activities need to be focused
in order to control
costs.
ALSTOM recommends directing initial sampling efforts towards
characterizing known
or suspected building materials and contaminant source areas rather
than starting
out with widespread grid sampling of the entire facility.
The investigation area can be expanded based on the results of this
initial directed
sampling approach if warranted. This approach has the advantage of
focusing sam-
pling efforts to optimize the amount of sampling and analysis
performed. The disad-
vantage is that the iterative process inherent in this approach can
take more time to
implement.
When planning for the environmental sampling activities, the
differences between in-
door and outdoor areas need to be made during planning must be
considered. Some
of these differences include items like:
� The different media
� Depth of sample collection
� Types of sources
� Sampling conditions such as confined space entry
For example, investigation outdoors around an underground storage
tank may re-
quire deep soil wells or groundwater sampling. Inside a building,
on the other hand,
investigations using wipe samples or bulk samples of surface
materials may be ap-
propriate.
It is also important to evaluate fully the potential for cross
contamination between in-
door and outdoor areas. For example, liquid spills indoors can have
migrated
through process drains to sanitary sewer systems or local out
falls. This potential
should also be evaluated.
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Regulatory A regulatory review should be performed concurrent with the

environmental investi-
review
gation activities. The regulatory review should identify:
� Applicable regulations relating to the constituents of concern
� Required analytical methods
� Minimum detection levels for sampling
� Target cleanup levels for any required re mediation
The regulatory review should include applicable federal, state, and
local require-
ments, as these can differ between various regulatory authorities. It
is helpful to
know the intended future use of the facility and factor this
information into the evalua-
tion of applicable regulatory requirements.
For example, target cleanup levels typically would be different for a
future industrial
use or limited exposure scenario versus the more stringent
requirements for public
use or a planned use with an unlimited time of exposure.
Equipment An equipment inventory is important to determine the equipment and
materials pre-
inventory
sent before the facility can be decommissioned. This applies to all
industrial process
equipment or measuring appliances and furnishings. This equipment
inventory can
support the development of process knowledge, and it is also a
consideration for
rendition and dismantling from both a cost and logistical perspective.
This information should be incorporated into the cost evaluation for
the decommis-
sioning options so a greater level of detail in the inventory is
beneficial for the accu-
racy of the cost comparisons. This is especially true if the equipment
and materials
have reuse or scrap value. This type of information is also helpful
when included in
contractor bidding specifications.
Building A building inspection also can provide valuable information for
deciding on decom-
inspection
missioning alternatives. Inspection of the facility design, materials
of construction,
and current condition can provide useful information to help direct
other portions of
the environmental assessment. The structural integrity of the building
is an important
factor to consider in evaluating whether the buildings should be
reused or demol-
ished. The architectural design of the building may also be a factor.
For example,
many old power plants have been converted into museums because the
large open
spaces inside the building in areas like the turbine hall readily lend
themselves to
adaptive reuse as exhibit space.
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Definition of For a safe decommissioning process the different material deposits

must be defined
the different
material de- and regularly controlled. The deposits need
posits
� A dike, to collect liquids
� A roof, to prevent from rain
Recondition- Reconditionable parts like blades must be separated
ing
Note
ALSTOM can not be liable for damages on recondition able parts if
they are dam-
aged by unsafe decommissioning.
Process For a safe decommissioning the process must be clearly defined
definition
� Permits
� Machines and tools
� Process
� Documentation
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3.3 Execution
3.3.1 Health and safety during decommissioning and deconstruction
This section deals with the safety aspects relevant to
decommissioning. Its focus is
on occupational and public protection. During decommissioning and
dismantling,
safety is ensured by a number of technical and administrative
measures. Their aim is
to protect the general public and the plant personnel against
inadmissible exposures
to hazards and hazardous situations. This protection has to be
ensured for all kinds
of incidents and accidents. It includes e.g. compliance with
industrial health and
safety standards for the handling of chemicals, the prevention of
accidents, etc.
Health and ALSTOM outlines the following good practice related to plant
decommissioning pro-
safety risk
assessment cedures:
� Members of staff and contractors must be aware of the hazards
associated with
the work they carry out and be able to determine whether the risks
involved are
acceptable.
� Risk assessment must be carried out, to determine the possibility
and conse-
quence of the hazards; if necessary, appropriate precautions must
be taken to
minimize the risk.
� All modifications - whether involving procedures, plant and
equipment, people or
substances - should be subject to formal management procedures.
The procedure should be designed and adapted to:
� Evidence from previous incidents - their cause and the means of
preventing them
� The intrinsic link between process definition and the validity of
the hazard evalua-
tion
� The options that are available in the design of safety measures
- Preventative measures (process control, instrumentation etc.)
- Protective measures (containment, venting, quenching, reaction
inhibition)
Good industry practice requires that plant decommissioning should not
be under-
taken without a safety review. This review should be traceable and
identify planned
or possible modifications of the following factors:
� Process conditions
� Operating methods
� Engineering methods
� Safety
� Environmental conditions
� Engineering hardware and design
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A form of risk assessment should then identify what hazards have been
created by
each modification that may affect plant or personnel safety, and what
action can be
taken to reduce or eliminate the risk. Additional hazards that could be
provoked and
must be considered are fire, explosion and loss of containment.
Modifications may affect other parts of the plant, which may be quite
remote from the
target. Therefore all parts of the plant should be analyzed in the course
of hazard
identification and risk assessments.
Factors that are crucial to the success and safe implementation of a plant
modifica-
tion procedure include:
� Corporate history
� Communication between different departments
� Recognition of authorized personnel
� Accurate recording and monitoring of changes to plant and process
3.3.2 Decommissioning procedures

The requirements for decommissioning vary, depending on the nature of the
plant
items to be decommissioned and on their former function. For
decommissioning of
plant operating procedures should be provided in the same way as for
commission-
ing. These procedures should be subject to hazard review and risk
assessment.
General measures that should be adopted for a common approach to decommis-
sioning include:
� Establish a permit to work system, which guarantees a sufficient level of
safety
during hazardous activities (includes, but is not limited to: working in
confined
space, hot work, working at heights, etc.).
� Establish a sufficient emergency and evacuation plan.
� Keep a site structure layout up to date.
� Establish communication with plant personnel to ensure that surrounding
plant
areas are prepared for decommissioning activity.
� Undertake removal of hazardous substances via a cleaning procedure, to
ensure
that each plant item is clean and empty, with particular consideration
where there
may be dead-legs where material is trapped.
� Plans of the disposal of items which may be contaminated by absorption of
haz-
ardous substances and chemical change.
� Mechanically isolate the plant item from other surrounding plant items by
physical
disconnection or fitting of blanks.
� Electrically and hydraulically isolate the plant item from power sources
by physi-
cal disconnection.
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� All plant items must be depressurized.

The In the following, the decommissioning process will be illustrated by
example. Prior to
decommis-
sioning the installation (Fig. 3-1 on page 3-7) is still largely in the same
technical condition as
process it was during operation. Now the equipment must be converted into the
"safe for de-
commissioning" status. Therefore, all steam supplies, connections to
the public
power connection and all operational wastes have to be removed. All
lubricating ma-
terials have to be removed and disposed of safely staff. Refer to the
current versions
of the Material Safety Data Sheets (MSDS) for advice on disposal.
Ensure that there
is no mixing of different kinds of materials.
When preparing the decommissioning activities, a detailed survey of the
plant's envi-
ronmental condition inventory is compiled. For this purpose,
environmental sampling
has been performed in all plant areas, and samples are taken and
evaluated. Once
an overview of the plant's inventory has been obtained, the
decommissioning proc-
ess can be planned in detail. It is also during this phase that
decisions are made
about any required decontamination and segmenting techniques.
ALSTOM assumes no liability for damage incurred by proceeding
unsuitable de-
commissioning.
The decommissioning of plant components usually begins with the removal
of in-
strumentation, electrical and piping and then continues with mechanical
decommis-
sioning. Emptied areas, e. g. parts of the turbine building, can be
used to install
equipment needed to disassemble, decontaminate, process and condition
the waste
and residual materials. Fig. 3-2 on page 3-9 displays schematically the
decommis-
sioning process.
The removed parts are disassembled and cut into pieces small enough in
size to be
easily handled. The characterization is used to decide about the
further usage of
each piece: either it will be conditioned so that it can be disposed as
waste, or it is
processed with the aim of clearing it for re-use or recycling (Residual
Material and
Waste Management).
The overall logistics for the management of waste and residual
materials are quite
substantial and represent a substantial cost factor.
During the decommissioning process, important systems remaining after
the opera-
tional phase, which are needed for further operation, are maintained
or, if necessary,
retrofitted. This concerns notably the ventilation systems, electric
power and media
supplies, communication system, etc.
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Note
If some parts will be reused on other units, they must be carefully dismantled
and
stored and someone from ALSTOM should be on site.

1 HP turbine 6 Internal steam pipe
2 IP turbine 7 Main stop valve
3 LP turbines 8 Intercept valve
4 Lube oil, control oil tank 9 Cross over pipe
5 Lube oil, control oil pipe
Fig. 3-1 General arrangement
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Material to be The following table shows the estimated amounts of material to be

disposed:
disposed of
Material Remark
Steel and iron
Stainless steel For lube oil and control oil piping
Copper Only for turbine cables
PVC Only for turbine cables
Lube oil Amount depends on unit size 15'000-
40'000 liters
Control fluid If available, amount it depends on
unit size max 1500 liters
Titanium For the L-1 and L-2 turbine blades
if available
Insulation On the turbine and internal steam
pipes
Aluminum For insulation cover
Table 5 Material to be disposed of
Decommis- See Fig. 3-2

sioning
sequence
Decommis- Decommissioning of facilities requires defined methods for a wide

range of tasks and
sioning
methods applications in connection with the decommissioning of the
facilities. The spectrum of
tasks reaches e. g. from the simple detaching of pipes to the
decommissioning and
segmentation of large vessels, the air - intake and exhaust
system, the decommis-
sioning of the turbine and generator and also of thick-walled
pipes.
Another important task is the further segmenting of large pieces
that have already
been dismantled, e. g. to allow for easy disposal. Apart from
various types of metal,
concrete components also have to be segmented, which - as e. g. in
the case of
some building structures - may contain a large proportion of
reinforcement steel.
The criteria governing the determination of the best suited
disassembly technique
are safety and the procedural parameters, e. g. cutting speed,
maximum separable
material thickness, release of dusts (aerosols), sound emission
level etc.
Decommis- Decommissioning and segmenting methods should be chosen according
to the fol-
sioning and
segmenting lowing criteria:
methods
� Suitability with respect to the type and the dimensions of the
material to be disas-
sembled
� Availability of space
� Protection aspects
� Load ability of the floor
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� Further processing of the material after disassembly

This means that disassembly methods must be applied in a range of very
different
areas and under very different conditions. It is obvious that this spectrum of
tasks
cannot be managed with one single technique. Thermal and mechanical cutting
and
segmenting techniques are described below
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Fig. 3-2 Decommissioning sequence
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Thermal cut- Thermal cutting and segmenting methods have in common that they
melt the mate-
ting and seg-
menting rial to be cut by means of a flame, an electric arc or a laser
beam. Then they remove
methods the molten material from the burr with a water or gas stream or
simply by gravita-
tional force. Thermal methods are far more frequently used for
metals than for con-
crete or conventional building materials. However, some methods are
suitable for
both material types. Depending on the method, the use of gaseous
media and the
melting-off of materials and cutting electrodes leads to emissions
of gas and dust.
However, these so-called aerosols and hydro sols can be controlled
by commercial
ventilation and filtering systems. Important thermal techniques
are:
� Oxyacetylene flame cutting
� Plasma arc cutting
� Electric arc cutting
� Electrical-discharge machining
� Laser beam cutting
Mechanical Mechanical cutting methods generate the burr by removing material
mechanically. In
cutting meth-
ods this case the material is neither melted nor burnt, and no cutting
gases are used, ei-
ther. The particles generated by cutting (shavings, dusts) can be
filtered compara-
tively easily. Mechanical cutting methods are used for metals and
building structures
alike. Important mechanical methods are:
� Conventional sawing
� Wire sawing
� Milling
� Grinding
� Shearing
� Water-abrasive cutting
� Explosive cutting
3.4 Documentation
Documenta- For decommissioning the following documentation can be used:
tion
� Dismantling & Reassembly ST
� Dismantling & Reassembly Auxiliary
� Relevant Supplier Documentation
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4 DISPOSAL
The disposal process must manage materials as follows:
� defining storage-containers and -places collecting
� sorting and marking
� safe storage
� environmental friendly disposal
4.1 Residual material and waste management

This section describes the management of residual materials and waste from
the de-
commissioning of facilities. It deals with the handling of waste that has to
be dis-
posed of in a repository and with the handling of residual materials, which
may be
recycled or conventionally disposed of.
One of the most important tasks in connection with the decommissioning of
facilities
is to manage the residual materials and waste. Here, the term "Residual
Material and
Waste Management" stands for all measures that aim at a safe, effective and
re-
source sparing handling of materials from facilities.
At the beginning, the activities comprise the disassembly of the material
and its sub-
sequent segmenting by means of the methods described in the previous
section.
The material must be sorted in accordance with the further processing needs
and
then stored.
There are multiple waste streams to be managed during the decommissioning.
They
should be analyzed in the decommissioning plan, their characteristics and
volumes
should be estimated, and treatment and disposal options should be evaluated.
Some
of the waste streams can be treated and disposed of locally, such as
recyclable met-
als and concrete waste.
Some mixed waste, hazardous waste and industrial waste such as oil, will be
shipped off site for disposal.
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4.1.1 Waste sorting and segregation

Waste sorting and segregation should be carried out depending on categories
for re-
cycling, such as:
� Plastic
� Rubber
� Paper
� Wood/timber
� Glass
� Textile
� Metal (i.e. aluminium can, steel metal, ferrous metal, and non-ferrous
metal)
� Oil, emulsion
� Solvent
The following table summarizes the primary types of waste streams
encountered
during decommissioning operations. The main sources are provided for
clarification.
The constituents that may be of environmental or health and safety concern
are also
summarized for each waste. The inclusion of a constituent in this column
does not
necessarily indicate that the constituent is always present, or that, if
the constituent
is present, it will be of high enough concentration to warrant concern.
Waste stream Main sources Possible
constituents
Absorbents Spill clean up Hydrocarbons,
production
chemicals,
solvent
Air emissions Vent gases, flare gases, blow NOx, SOx, HxS,
COx, VOC,
down from bulk chemicals hydrocarbons,
carbons, par-
ticulates, PAH,
BTEX
Contaminated soil Spill/leaks Hydrocarbons,
heavy metals,
salts, treating
chemicals
Contaminated drainage � Rainwater run-off Salts, heavy
metals, solids,
water � Rig water production
chemicals, deter-
� Process water gents,
hydrocarbons
� Wash water
Domestic sewage � Social facilities BOD, solids,
detergents, coli-
form bacteria
Electric refuse � Pumps Heavy metals,
plastics
� Motors
Electronic refuse � Control system Heavy metals,
plastics
Fire fighting agents � Fire protection equip- Halons, CFC's,
HCFCs, fire
ment/facilities fighting foams
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Waste stream Main sources Possible

constituents
Industrial refuse Cleaning materials Hydrocarbons,
plastics
Industrial waste � Batteries Acid, Alkali,
heavy metals
� Capacitors
Insulation material Rock wool, glass
wool, plas-
tics
Maintenance waste � Sandblasts Heavy metals,
hydrocarbons,
� Greases solids, solvents
� Lube oils
� Filters
� Oil-based muds and cut-
tings
Paint materials � Paints Heavy metals,
solvents, hy-
� Thinner drocarbons
� Coatings
Piping sludges Piping cleaning operations Inorganic salts,
heavy met-
als, solids,
production chemi-
cals
Process water Engine cooling water Hydrocarbons,
treating
chemicals
Production chemicals � Chemical containers Demulsifier,
corrosion inhibi-
� Spent fluids tors, wax
inhibitors, scale
� Sludges inhibitors,
defoamers, oxygen
� Contaminated chemicals scavengers,
biocides, coagu-
lants,
flocculants
Scrap metals � Abandoned equipment and Heavy metal
constructions
� Used pipelines
� Used process equipment
� Used tanks
� Electrical cables
� Empty drums
� Used tabulars
Tank and vessel bottom � Separation tank sediments Salts, heavy
metals, wastes
� Storage tanks sediments solids,
production chemicals,
� Water drain tank sediments hydrocarbons,
PAHs
Waste lubricants Equipment lube oil Organics, heavy
metals
Table 6 Waste stream types
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4.2 Disposal-relevant components

Waste stream Main sources
Operating media Never ditch waste to the soil, consign it to special
agencies or dis-
posal places.
Carbon steel Consign to a recycling place.
Exotic heavy met- Consign to a recycling place.
als
Filter cartridges Consign to the vendor or to special agencies or
disposal places.
Contaminated ma- Consign to the vendor or to special agencies or
disposal places.
terial
Insulation material Consign to the vendor or to special agencies or
disposal places.
Pumps, fans, mo- Dismantle into individual components and dispose of
properly ac-
tors, etc. cording to these instructions.
Disposal of seals Consign to the vendor or to special agencies or
disposal places.
Parts for recondi- Parts should be sorted for reconditioning.
tioning
Table 7 Waste stream types
Note
Every country can have its own local laws, directives, and guidelines for the
dis-
posal of material. All applicable local rules must be strictly followed.
4.3 General refuse

The types of general waste are classified below:
� General debris
� Workforce waste
� Wood/timber
� Scrap metals
The storage of general refuse can have an impact on the environment. It can
impact
water quality, if waste enters nearby water bodies, emit odors or have visual
impacts.
The site may also attract pests and vermin if the waste storage areas are not
well
maintained and cleaned regularly. In addition, disposal of waste at sites
other than
approved waste transfer stations or disposal facilities can also have
environmental
impacts.
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4.4 Chemical waste

Most of the lubricating agents used may be classified by local regulation
as chemical
waste. Please refer to the Material Safety Data Sheets and applicable local
regula-
tion for advice on compliant handling, transportation, marking, storage and
disposal.
4.5 Handling and disposal of hazardous materials on decommis-

sioning sites
4.5.1 Introduction
Certain materials are considered hazardous because they are:
� toxic, caustic, irritating, highly inflammable, explosive, incendiary,
� carcinogenic, sterilizing, mutagenic, harmful to the environment.
Materials can have one such property, or several in combination. Whereas
individual
properties occur acutely, such as cauterization, others may have a gradual
or
chronic effect. The health consequences may thus often take years to
manifest.
Mistakes made in the handling of hazardous materials can result in
irreversible dam-
age to human health or even death. Grave environmental damage can be caused
by
� careless handling of materials
� mistakes in disposing of hazardous materials
� accidents
Elimination of such environmental damage can provoke considerable expenses
(e.
g. waste material removal, treatment of drinking water, etc.)
Note
Health and environmental protection require discipline in observing the
basic rules
for handling and disposal of hazardous materials.
This section serves as a guide to various categories of hazardous materials
and is
structured as follows:
� Category
� Examples, typical representatives
� Type of work contact with materials of this category is possible
� General effects of materials of this category
� Important information about handling and disposal
� References to more detailed literature, check lists, etc.
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MA - HTGD691892V9000
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ALSTOM
Steam
Turbines
Note
The hazard symbols, identifiers and nomenclature are based on EU and local
law
and can differ from the respective country-specific regulations.
4.5.2 General guidelines for handling & disposal of hazardous materials

� Hazardous materials must always be labelled according to regulations
� Only specially trained personnel is authorized to handle hazardous
materials
� Hazardous materials must always be stored separated from other materials
� Unknown materials must be treated as hazardous materials
� Appropriate personnel protective equipment must be worn when handling
haz-
ards
� All forms of contact should be avoided (skin, eyes, nose, mouth)
according to Ma-
terial safety Data Sheets (MSDS)
� Smoking, eating and drinking are prohibited in locations where hazardous
materi-
als are stored or handled
� Cleanliness must be maintained at locations where hazardous materials are
stored or handled
� Working clothes and personal clothing must be kept separated, and hands
must
be washed frequently
� Hazardous materials must never be discharged into the environment and
must be
disposed of according to regulation
� Choose authorized disposal service companies disposing of hazardous
materials
must produce records for their clients, to prove correctness of their
methods
� Records must be kept for the disposal of hazardous materials according to
local
legislation
� "First Aid" measures and emergency telephone numbers must be made known
on
site
� In case of accidents, always take measures immediately
� In case of accidents with acute danger to life and health, always:
- Call rescue squads and notify neighbors and authorities
- If the air is contaminated (gas cloud): Evacuate the area
- If water is contaminated: Close off the source
- If the ground is contaminated: Close off the source, mark and cover
the area,
remove contaminated soil and provide for its disposal (special
waste)
en HTGD 693 000 V0140 A
1889
WP4140
4.5.3 Handling fibrous materials

Examples Fiberglass, ceramic fibres
Applications Fibrous materials are often used for insulation and manually
inserted into cavities.
Hazards For other fibres, the "asbestaos"-effect is presumed, although not
established.
caused by
fibrous mate- Therefore the safety measures applying to work with asbestos also
apply to work
rials with glass and ceramic fibres.
Handling and When processing fibrous materials, the breathing passages must be
protected by
disposal
appropriate masks. Avoid the formation of fine dust (do not use
high-speed equip-
ment). Suction clean any resulting dust when-ever possible.
Guidelines � Wear a protective mask when working with insulation (FFP3S)
4.5.4 Handling poisons

Examples Hydrofluoric acid, sulfuric acid, propyl alcohol
Applications Toxic materials are used in metal surface treatment and for
decalcifying coolant wa-
ter.
Hazards Absorbance of or contact with solid, liquid or gaseous materials
results in empoison-
caused by
poisons ing. Poisons can be formed out of otherwise harmless components by
uncontrolled
chemical reactions (e.g.: from plastics).
Handling and Handling and disposal of poisons is subject to strict regulations.
These can be found
disposal
in the Federal Law on Trade in Toxic Substances, the Environmental
Protection Law
and associated ordinances. Trade includes purchase, storage,
transport, handling
and disposal. Cleanliness when working with poisons is of paramount
importance.
Records must be kept of all purchase and disposal of poisons.
Guidelines � Only specially trained personnel are permitted to handle poisons
� Poisons must be labelled as such clearly and so as to be
understood by anyone
� Never transfer poisons to third parties except to a specialized
disposal firm
� Poisons must be kept sealed and stored separately from other
materials
� When handling poisons, wear the prescribed personal safety
equipment
� Poisons and materials which are contaminated with poisons
(cleaning rags, work
apparel, etc.) must not enter the environment
� Poisons are to be disposed of according to regulation as special
waste
� Companies who dispose of poisons must be monitored by the client
as to how
this is performed
1890 HTGD 693 000 V0140 A

en
MA -
HTGD691892V9000 -
ALSTOM
Steam
Turbines
� If local regulated disposal is not possible, hazardous materials must

be returned
to the point of purchase or disposed of within at an appropriate place
� In case of accidents, provide "First Aid" and summon a physician
� Poison-contaminated materials are to be treated and disposed of as
poisons
Labeling of poisons for commercial/industrial use
Labeling poisons which are classified individually by local authorities.
Note
The following list meets only the minimum requirements for labeling of
poisons.
Example � Instructions for use if prescribed

� Additional information such as weight
� Code No. on request of the seller
� Hazard symbol
� Content
� Warning labels/notices
� Any data as per local regulations
Guidelines for container and drum requirements
� Prevent any release of poison.
� Reusable containers must be able to be resealed.
� It should be impossible to confuse with drums containing non-toxic
materials.
� Use the poison band for marking (see public traffic).
� Poison is to be kept in the container in which it was purchased. The
same label-
ing regulations apply when refilling as for the original barrel.
� If poisons are used continuously, they may remain at the workstation in
small
amounts if it is ensured that only authorized persons have access.
en HTGD 693 000 V0140 A

1891
WP4140
4.5.5 Handling acids, lyes

Examples Hydrochloric acid, nitric acid, hydrofluoric acid, sulfuric acid,
caustic soda, caustic
potash solution, quicklime
Applications Acids are used for metal treatment (etching), in batteries or for
water treatment. Lyes
are used to neutralize acidic solutions. Caustic calcium hydroxide
is released when
quickening lime.
Hazards The caustic effect of acids and lyes is hazardous, with
irreversible damage in some
caused by
acids and lyes cases (loss of sight). Significant heat is generated when reacting
with water. In addi-
tion to the caustic effect, these substances may be poisonous and
incendiary. Acids
and lyes can react strongly with other chemicals and then release
health endanger-
ing materials into the vicinity (for example: ammonia and
hydrochloric acid form am-
monium chloride).
Guidelines � Drums containing acids and lyes must be properly labelled, must
stand safely and
must be reachable in a safe way.
� Acids and lyes must always be stored away from other materials.
� Avoid contact of any kind with acids and lyes.
� When working always wear personal safety equipment.
� When accidents with acids and lyes occur, render "First Aid" and
summon a phy-
sician, rinse skin and eyes for at least 20 minutes with water -
IMMEDIATELY.
� Label contaminated materials and dispose of them as special
waste.
� Deflagration: Gas alarm, notify neighbors and authorities.
� For spillage into sewers and water supplies: Close off source,
inform neighbors
and authorities.
� For seepage into the ground: Close off source, inform neighbors
and authorities,
remove and dispose of soil.
4.5.6 Handling solvents and products containing solvents and products

con-
taining solvents"
Examples Products classified as solvents and solvent-containing include:
Gasoline, cleaners,
alcohols, coolants, paints, resins, varnishes, adhesives and
fillers. Solvents and res-
ins frequently used at construction sites are listed separately.
Applications Solvents are generally used for cleaning purposes, especially for
degreasing. Prod-
ucts containing solvents are used in dissolved (liquid) form,
after a short drying
phase (the solvent evaporates into the air) the desired product
assumes its final
form.
1892 HTGD 693 000 V0140 A

en
MA -
HTGD691892V9000 -
Decommissioning & Disposal Guideline
for ALSTOM
Steam Turbines
Hazards This group of materials has large number of various hazardous

properties: Vapors
from solvents or products containing solvents are often explosive or
highly flamma-
ble, cause irritation of the skin, eyes and breathing passages, can
lead to chronic
damage to the skin and internal organs (allergies, cancer), may be
poisonous, can
be heavier than air and accumulate in low areas (danger of
asphyxiation, especially
when working alone).
Handling and Always keep solvents and products containing solvents away from
flame sources
disposal
there may be enough vapor even in empty containers to cause an
explosion! Good
air supply and circulation systems are always a MUST! Inform
colleagues in your
area. Do not allow solvents or products containing solvents to enter
the environment!
Guidelines � Drums with solvent-containing materials must be properly labelled
and kept tightly
closed.
� Always store products containing solvents separate from other
materials.
� Avoid contact with solvents (skin, eyes, nose, mouth).
� When working always wear personal safety equipment.
� Do not allow solvents to be released into the air (health
protection, environment).
� Label your work area: Fire and explosion hazard.
� Careful with "empty" containers and canisters: Explosion hazard!
� Do not allow paints and varnishes or unhardened resins to dry in
the air.
� Do not allow solvents to enter the water (fire and explosion
hazard).
� If necessary allow unhardened resins to harden and dispose of as
refuse.
� Always dispose of materials containing solvents as special waste.
� Companies who dispose of solvents must be inspected for how they
perform this.
� Feeling unwell, dizziness, vomiting: Consult a physician.
� Spills into the sewer system and water supply: Close off the
source, inform
neighbors and authorities.
� For seepage into the ground: Close off source, inform neighbors
and authorities,
remove and dispose of soil.
en HTGD 693 000 V0140 A
1893
4.5.7 Handling two-component resins (paints, varnishes, resins)

Applications These materials are used in paints and varnishes, adhesives,
fillers, floor coverings
and insulation. There are generally two-components: resin and
hardeners, as well as
a number of additives: solvents, foaming agents, foam stabilizers,
fillers, pigments
and others. Unhardened components have properties similar to
solvents. When
processing hardened components, heating causes harmful vapors, and
mechanical
processing can generate allergenic dust. Harmful mists are created
when working
with paints and varnishes.
Hazards However, decommission only resins with expended reactions are
expected. They are
to be disposed complying with local legislation.
Contact results in skin and eye irritation, allergies and eczema.
When ingested the
materials are poisonous and cause organ damage and changes in the
blood count.
Painting and varnishing are especially risky for the breathing
passages (asthma, dif-
ficulty breathing, coughing, sometimes accompanied by fever).
Handling and Whereas leftover paint and varnish, as well as individual components
of resins, must
disposal
be disposed of under supervision as special waste. Hardened resins
and fillers can
be disposed of as normal refuse.
4.5.8 Handling oils, lubricants, oily emulsions
WARNING
Slippery
Hazards due to wet or oily walk ways may be slippery which may cause
seri-
ous injury.
Keep walk ways clean
Examples This group includes control fluid, lube oil, greases and oily
emulsions.
Applications Control fluid and lube oil is used for speed governing and bearing
lubrication.
Hazards All materials belonging to this category have the property of
quickly penetrating the
skin. Except for aqueous emulsions, all oils are more or less
inflammable. Fires of
oily material cannot be extinguished with water, but rather only
with special fire re-
tardants.
Oils do not easily break down biologically, and when in water and
soil, it will destroy
the ecosystems for animals, plants and micro-organisms and cause
long-term dam-
age to natural circulation.
1894 HTGD 693 000 V0140 A
en
MA -
HTGD691892V9000 -
Steam Turbines
Handling and Observe cleanliness. Avoid skin contact and use skin protection and
safety precau-
disposal
tions. Do not allow these materials to enter the environment,
neither during use, nor
transport, nor during storage. Take precautions against this.
Guidelines � Drums must be properly labelled and kept tightly closed.
� Drums must be placed in collecting tray.
� Store oily materials separate from solvents (fire hazard).
� Avoid any contact with oil-containing materials (skin, eyes, nose,
mouth).
� When working with these materials, always wear safety equipment
(gloves).
� Do not allow oils to enter the ground or water (will suffocate
living creatures).
� Secure drums against spills, use caution when refilling.
� Oil-containing materials must always be disposed of as special
waste.
� Companies which dispose of oils must provide verification to the
client as to how
this is performed.
� Spills into the sewer system and bodies of water: Close off the
source, inform
neighbors and the authorities.
� Seepage into the soil: Close off source, inform neighbors and the
authorities, re-
move and dispose of soil.
All safety measures must be convenient with the fire safety
dispositive.
4.6 Storage of reusable components

Components may be usable for other use, internal or external
� The components must be stored clean, safely and preserved
� Maintenance during the storage must be planned and executed
periodically
4.7 Return to the manufacturer

In case of usableness or disposal the components can be returned in
some circum-
stances to the manufacturer. This must be checked by the
decommissioning plan-
ning.
4.8 Material Safety Data Sheets

Material Safety Data Sheets for materials and media must be
applicable and avail-
able, this is subject to disposal.
en HTGD 693 000 V0140 A
1895
Blank Page
HTGD691892V9000
1896 HTGD 693 000 V0140 A en

MA - HTGD Index
MA - HTGD Index
en HTGD 693 000 V0140 A 1897

1 HTGD630122.....636
1BSE001367 ff.....467 HTGD630136.....658
1BSE001373 ff.....469 HTGD630147.....664
1BSE001374 ff.....471 HTGD630178.....668
1BSE001375 ff.....473 HTGD667205 ff.....699
1BSE001376 ff.....475 HTGD667206 ff.....701
1BSE001377 ff.....477 HTGD667229 ff.....703
1BSE001405 ff.....479 HTGD667230 ff.....705
1BSE001637.....486 HTGD667231 ff.....707
1BSE001715 ff.....503 HTGD667232 ff.....709
1BSE001848 ff.....505 HTGD667233 ff.....711
1BSE001957 ff.....507 HTGD667235 ff.....713
1BSE001958 ff.....509 HTGD667236 ff.....715
1BSE501022 ff.....511 HTGD667237 ff.....717
1BSE501152.....526 HTGD667238 ff.....719
1BSE501156.....546 HTGD667239 ff.....721
1BSE501157.....554 HTGD667240 ff.....723
1BSE501163.....596 HTGD667241 ff.....725
1BSE501424.....610 HTGD667244 ff.....727
H HTGD667247 ff.....731
HTGD.....1898 HTGD667248 ff.....733
HTGD090028V0004B.....206 HTGD667249 ff.....735
HTGD090117V0001V.....1830 HTGD667250 ff.....737
HTGD090185V9000A.....156 HTGD667251 ff.....739
HTGD090185V9001A.....168 HTGD667252 ff.....741
HTGD090185V9002.....180 HTGD667254 ff.....743
HTGD090269V0001F.....138 HTGD667255 ff.....745
HTGD090319V9000.....222 HTGD667256 ff.....747
HTGD090325V9000.....198 HTGD667257 ff.....749
HTGD090387V9000.....190 HTGD667259 ff.....751
HTGD090440V0001H.....146 HTGD667260 ff.....753
HTGD090486V0001G.....124 HTGD667261 ff.....755
HTGD090550V001F.....114 HTGD667262 ff.....757
HTGD479469 ff.....799 HTGD667264 ff.....761
HTGD479470 ff.....801 HTGD667265 ff.....763
HTGD499340 ff.....621 HTGD667266 ff.....765
HTGD499343 ff.....623 HTGD667267 ff.....767
HTGD499345 ff.....625 HTGD667268 ff.....769
HTGD630064 ff.....627 HTGD667269 ff.....771
1898 HTGD 693 000 V0140 A en

MA - HTGD Index
HTGD667270 ff.....773 HTGD691735V0004B ff.....1081

HTGD667272 ff.....777 HTGD691765V0002A ff.....1119
HTGD667273.....780 HTGD691767V0004 ff.....1143
HTGD667275 ff.....783 HTGD691768V0001B ff.....1148
HTGD667276 ff.....785 HTGD691780V0001A.....1653
HTGD667277 ff.....787 HTGD691780V0101D.....1692
HTGD667459 ff.....789 HTGD691785V0001 ff.....1158
HTGD672031 ff.....791 HTGD691805V0002A ff.....1162
HTGD672059.....794 HTGD691830V0001A ff.....1172
HTGD690038V0001E.....86 HTGD691842V0003B ff.....1184
HTGD690059V9000.....264 HTGD691842V0005 ff.....1208
HTGD690082V9000.....1644 HTGD691855V0001A ff.....1222
HTGD690143V9014.....1720 HTGD691883V9000.....1791
HTGD690147V0001A.....132 HTGD691888V0001B ff.....1242
HTGD690148V0001B.....350 HTGD691892V9000.....1896
HTGD690182V9000.....1704 HTGD691893V0001 ff.....1290
HTGD690411V9000.....1840 HTGD691894V0001 ff.....1296
HTGD690520V9008.....1638 HTGD691895V0001 ff.....1300
HTGD690524V9026.....1734 HTGD693010V9024.....1810
HTGD690555V0001A.....214 HTGD693011V9020.....1624
HTGD690743V0001A.....1846 HTGD693015V0001.....230
HTGD690744V0001C.....1854 HTGD693027V9005.....74
HTGD691538D0401 ff.....803 HTGD693028V9005.....30
HTGD691538D0410.....808 HTGD693029V9001.....1630
HTGD691538D0413.....812 HTGD693038V9009.....1766
HTGD691538D0414.....816 HTGD800002V0012 ff.....444
HTGD691538V0004.....286 HTGD800011V0002 ff.....360
HTGD691538V0005.....343 HTGD800031V0005B ff.....454
HTGD691539V0001A.....820 HTGD800035V0010 ff.....430
HTGD691613V0002A.....836 HTGD800035V0013 ff.....408
HTGD691631V0002A.....862 HTGD800040V0026 ff.....376
HTGD691697V0003 ff.....987 HTGD800047V0011 ff.....450
HTGD691723V0001B ff.....1019 HTGD800059V0021 ff.....366
HTGD691732V0001C ff.....1041 HTGD800073V0024 ff.....356
HTGD691735V0003C ff.....1051 HTGD800205V0004 ff.....404
HTGD Index
en HTGD 693 000 V0140 A 1899

Blank Page
1900 HTGD 693 000 V0140 A en

MA - KKS Index
MA - KKS Index
en HTGD 693 000 V0140 A 1901

L MAC10AA021.....69
LB.....433 MAC10CG201 ff.....900
LB ff.....779, 780 MAC10CP001 ff.....901
M MAC10CP006 ff.....902
MA.....1507 MAC10CP031 ff.....902
MA ff.....7, 23, 31, 87, 103, 115, 125, 133, MAC10CP032 ff.....903
139, 147, 157, 169, 181, 191, 199, 207, 215, MAC10CP033 ff.....903
223, 231, 265, 287, 345, 351, 459, 883, MAC10CP071 ff.....904
1855, 1897 MAC10CP072 ff.....904
MAA10.....69, 1472, 1509, 1514 MAC10CP081 ff.....905
MAA10 ff.....382, 404, 1349 MAC10CP082 ff.....905
MAA10CF001 ff.....893 MAC10CT010.....1510
MAA10CP001 ff.....893 MAC10CT010 ff.....906
MAA10CT005.....1510 MAC10CT021 ff.....906
MAA10CT005 ff.....356, 895 MAC10CT081 ff.....907
MAA10CT005A ff.....895 MAC10CT082 ff.....907
MAA10CT005B ff.....895 MAC10CY011 ff.....908
MAA10CT005C ff.....896 MAC10GZ001.....901
MAA10CT010.....69 MAC10HA420.....69, 1510
MAA10CT010 ff.....358, 896 MAC31.....69
MAA10CT026 ff.....897 MAC31 ff.....410, 1645, 1655
MAA10CT032 ff.....897 MAC31AA001.....69
MAA10CT033 ff.....898 MAC31GD001.....909
MAA10GZ001.....893, 894 MAC31GD002.....910
MAA10HA410.....69, 1510 MAC80 ff.....1693
MAA12 ff.....360, 1631 MAC80AA001.....69
MAA12AA001.....69, 1427, 1431, 1459, MAC80CG201 ff.....911
1508, 1567, 1575 MAC80CP002 ff.....912
MAA12AA001 ff.....362, 366 MAD20.....1394, 1600
MAA12AA011.....1443, 1447, 1465, 1555, MAD20 ff.....430, 432
1561 MAD20CS001 ff.....912
MAA12AA011 ff.....372, 376 MAD20CS002 ff.....913
MAA12BQ001.....69, 1427, 1578 MAD20CS003 ff.....913
MAA12CG001 ff.....898 MAD20CY004 ff.....914
MAA12GD001.....898 MAD20CY011 ff.....914
MAA12GD002.....899 MAD20CY022 ff.....916
MAC10.....69, 1495, 1644, 1740, 1745, MAD20CY025 ff.....916
1752, 1757 MAD20GD001.....914, 915
MAC10 ff.....406, 408, 1639 MAD21.....69, 1408, 1410, 1413, 1507
1902 HTGD 693 000 V0140 A

en
MA - KKS Index
MAD21 ff.....444, 1705 MAV21AP021.....1803

MAD21CT001.....1407 MAV21AP031.....1801, 1803
MAD21CT001 ff.....917 MAV21AT021.....1799
MAD21CT003.....1407 MAV21CP011 ff.....927
MAD21CT005.....1407 MAV21CP021 ff.....927
MAD21GD001.....917, 918 MAV21CP031 ff.....928
MAD21GD002.....918, 919 MAV21CT002 ff.....928
MAD50.....69, 1507 MAV22AC001.....1802
MAD50GD001.....908, 920 MAV22AC002.....1798
MAD51.....69, 1518, 1747, 1752 MAV22CT002 ff.....929
MAD51 ff.....448, 1721, 1735 MAV22DT001.....1799, 1802
MAD51GD001.....921 MAV23AT001.....1801, 1806
MAK21.....1416, 1582 MAV23CP001.....1802
MAK80.....69, 1782 MAV23CP001 ff.....929
MAK80 ff.....1767 MAV40AA503.....1807, 1808
MAK80AA015.....1782 MAV40AA505.....1807
MAK80BP010.....1782 MAV40CP002 ff.....930
MAK80CG006.....1782 MAV40CP003 ff.....931
MAK80CG006 ff.....922 MAV40CP004.....1807
MAK80CG021.....1782 MAV40CP051 ff.....933
MAK80CG021 ff.....923 MAV40CP052 ff.....933
MAK80CG111 ff.....923 MAV40CP503.....1807
MAK80CG121 ff.....924 MAV40CP503 ff.....934
MAK80EA011.....1782 MAV40CP504 ff.....934
MAK80EE211 ff.....924 MAV40CP505.....1807
MAV02.....1798 MAV40CP505 ff.....935
MAV02AN001.....1801 MAV40CP506 ff.....935
MAV02AT001.....1800, 1801 MAV40CT001.....1806
MAV02BB001.....1798, 1800 MAV40CT001 ff.....936
MAV02CL001 ff.....925 MAV40CT002.....1806
MAV02CP001 ff.....926 MAV40CT002 ff.....936
MAV02CT001.....1804, 1806 MAV40DP001.....1799, 1801
MAV02CT001 ff.....926 MAV50AP001.....1801, 1803
MAV02GD001.....925, 929, 931, 932, 936 MAV50CP001.....1808
MAV02GD002.....957, 958, 960, 961 MAV50DP001.....1803
MAV02GD003.....1804 MAV52CP001 ff.....937
MAV21 ff.....763 MAV55CP001 ff.....938
MAV21AA001.....1799 MAV70AT001.....1799
MAV21AP011.....1799 MAV70CT021 ff.....938
MAV21AP011 ff.....450 MAV70CT023 ff.....939
en HTGD 693 000 V0140 A 1903

MAV70CT051 ff.....939 MAX15.....1809

MAV70CT053 ff.....940 MAX15BB001.....1804, 1805
MAV91CE001 ff.....940 MAX15CP001 ff.....959
MAV91CE002 ff.....941 MAX15DP001.....1804, 1805
MAV91CE003 ff.....941 MAX16CP002 ff.....959
MAV91CF001 ff.....942 MAX43 ff.....452, 1841, 1847
MAV91CL001 ff.....942 MAX43AA111.....453
MAV91CT002 ff.....943 MAX44 ff.....454
MAV91CT006 ff.....943 MAX44AA001.....1801
MAW10CG011 ff.....944 MAX44AA301.....1809
MAW10CP001 ff.....944 MAX44AA303.....1809
MAW15CG061 ff.....945 MAX44CG001 ff.....960
MAW15CP001 ff.....945 MAX44CP002.....1809
MAW15CP002 ff.....946 MAX44CP501 ff.....962
MAW15CP003 ff.....947 MAX44CP502 ff.....963
MAW15CP011 ff.....947 MAX44CP503 ff.....963
MAW15CT001 ff.....948 MKA10CT001 ff.....964
MAW15CT002 ff.....948 MKA10CT002 ff.....964
MAW15CT003 ff.....949 MKA10CT003 ff.....965
MAW15GZ001.....945 MKA10CT004 ff.....965
MAW30CL001 ff.....949 MKA10CT005 ff.....966
MAW30CP001 ff.....950 MKA10CT006 ff.....966
MAW30CP002 ff.....950 MKA10CT007 ff.....967
MAW30CP003 ff.....951 MKA10CT008 ff.....967
MAW30CT002 ff.....951 MKA10CT009 ff.....968
MAW30CT011 ff.....952 MKA13CL011 ff.....968
MAW30CT012 ff.....952 MKA13CT011 ff.....969
MAX00EW001.....953, 954, 955 MKA13CT016 ff.....969
MAX00EW002.....953, 954, 955 MKA13CT021 ff.....970
MAX00EW011 ff.....953 MKA13CT026 ff.....970
MAX11 ff.....1831 MKA13CT031 ff.....971
MAX11AP001.....1801 MKD10CT001 ff.....971
MAX11AP002.....1804, 1805 MKD10CY021 ff.....972
MAX11CP002 ff.....956 MKD10CY022 ff.....972
MAX11CP031 ff.....957 MKD11CT001 ff.....973
MAX11CP501.....1799 MKD20CP001 ff.....973
MAX11DP001.....1801, 1805 MKD20CT001 ff.....974
MAX13AT001.....1808 MKD20CY021 ff.....974
MAX13CP001.....1801, 1804, 1805 MKD20CY022 ff.....975
MAX13CP001 ff.....958 MKD21CP001 ff.....975
1904 HTGD 693 000 V0140 A en

MA - KKS Index
MKD21CT001 ff.....976
KKS Index
en HTGD 693 000 V0140 A 1905

Blank Page
1906 HTGD 693 000 V0140 A en

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OPERATION & MAINTENANCE BOOK WP4110 & WP4140

Operation & Maintenance Book

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en HTGD 693 000 V0140 A

2 HTGD 693 000 V0140 A

WP4110 & WP4140

Operation & Maintenance Book WP4110 & WP4140 Steam

en HTGD 693 000 V0140 A

MAA10CT005/010- HTGD693029V9001 - Temperature

4 HTGD 693 000 V0140 A

en HTGD 693 000 V0140 A

6 HTGD 693 000 V0140 A en

en HTGD 693 000 V0140 A 7

8 HTGD 693 000 V0140 A

General Safety Rules

4.1 Working with Safety in

en HTGD 693 000 V0140 A

4.10.1 Shipment, Machine

10 HTGD 693 000 V0140 A

This document comprises four sections:

en HTGD 693 000 V0140 A

1.1 Use as Designed

1.2 Identification of Residual Dangers and Dangerous Areas

12 HTGD 693 000 V0140 A

Operating safety is no longer guaranteed if the plant is used

1.4 Components and Spare Parts

1.5 Exclusions from Liability

en HTGD 693 000 V0140 A

c) force majeure (Acts of God) and normal wear

14 HTGD 693 000 V0140 A

2 INFORMATION FOR THE OPERATOR / OWNER OF THE

2.1 Preparation of Staff

2.2 Safety and Monitoring Equipment

2.3 Safety Rules that Apply

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2.4 Your Responsibilities

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2.5 Further Duties of the Operator

3 INSTRUCTIONS FOR THE SUPERVISOR

3.1 Authorized Operation

3.2 Following Existing Safety Rules

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b) Familiarize yourself with the operating instructions and the activities

3.4 Manning the Operating Stand

4 INSTRUCTIONS FOR THE OPERATING AND MAINTENANCE

4.1 Working with Safety in Mind

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f) Wear protective clothing where necessary or prescribed

4.2 Safe Condition for Maintenance Work

4.3 Safety Rules that Apply

4.4 Questions concerning Safety

4.5 Conduct following Malfunctions

4.6 Emergency Shut-down

4.7 Denial of Access to Unauthorized Individuals

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4.8 Reporting Damage and Defects

4.9 Special Tools and Spare Parts

4.10 Special Dangers

4.10.2 Initial Start-up after a Standstill for Maintenance Work

4.10.4 Protective Covers

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4.10.5 Danger of Fire

4.10.7 Danger of Explosions

4.10.8 Power Supply System