TRT Overhaul Document

STANDARD OPERATING PROCEDURES
Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01/04/2009
SOP No. HBF/PSP-MECH/01/SOP-GCP-29 Effective Date 27/07/2020 REVISION No 2.02

SOP DESCRIPTION TRT OVERHAULING & MAINTENANCE Section MECH. / GCP
DEPARTMENT H BLAST FURNACE Page 1 to 188
Step Activity Associated Responsibility Process / tools / PPEs (HOW)

Remarks / Reference
No. (WHAT) Requirements/Hazards/Impacts (WHO)
JOB IS MENTION DAY
BY DAY GIVEN IN
SAFETY: NO IMPACT TSL AUTHORIZ E
A) TOOL BOX MEETING MUST BE DONE. MANUAL, IT WILL DONE
B) RAISE PERMIT TO WORK IN FORM MAY DELAY OR EARLIER
CLEARENCE & ENVIRONM ENT: NO IMPACT PERSON/
1 WORK PERMIT QUALITY: CLEARNACE FORM CONTRA CTOR
EHSMSM/WORKS/446/4007 AS WELL AS.
C) RAISE GAS CLEARENCE IN FORM
PROPERLY FILLED UP SUPERVISOR
O P EHSMSM/WORKS/446/4001 WORK PERMIT TAKE AND

RETURN PER DAY
BASIS.
SAFETY: FALLING HAZARD,
d S A)
B)
C)
CLOSE TEV.
CLOSE BUTTER FLY VALVE BEFORE GV # 004.
CLOSE GV # 004 AND GV # 005.
i
FINGER INJURY TSL AUTHORIZ E IT IS WORK OF MORE
l
PRE-WORK D) OPEN VENT VAVLE. THEN 1 DAY.
ENVIRONM ENT: GASEOUS, NOISY, PERSON/
2
a
BEFORE TRT E) N2 PURGING DONE.
DUSTY. CONTRA CTOR
ISOLATION. F) CLOSE ALL WATER LINE VALVE & ALL GCTK THESE JOBS DONE ONLY
QUALITY: MUST BE DONE AS PER SUPERVISOR IN SHUT DOWN DURATION.
V
LEVEL ZERO.
DOCUMENTS.
G) OIL EMERGENCY TANK MUST BE TAKE LEVEL
ZERO.
SAFETY: FALLING HAZARD,
FINGER INJURY TSL AUTHORIZ E
A) POSITIV E ISOLATION TO BE DONE AND KEEP
POSITIV E ENVIRONM ENT: GASEOUS, NOISY, PERSON/ ESI ANNEXURE
3 ISOLATION AND DUSTY. CONTRA CTOR
KEY IN PROPER POSITION.
ATTACHED
B) REFFER ESI DOUCUMENT OF DEPT
QUALITY: FORM PROPERLY FILLED SUPERVISOR
UP
O P
Name and Design –
PREPARED BY
NIRANJAN D. HONAP, Jr.Engg.
APPROVED BY
Name and Design—SUMIT RANJAN, MANAGER
d S
Signature with Date
Printed By -NIRANJAN HONAP(161030) Print valid till - 27-Aug-2020

Signature with Date
Printed on - 17-Aug-2020
a l i
SOP Valid Till - 27-Jul-2021
SAFETY: SLIP, TRIP AND FALLING
TSL AUTHORIZ E
HAZARD, FINGER INJURY OVER HAULING DONE AS PER MANUAL
START THE PERSON/
4. OVER HAULING
ENVIRONM ENT: NOISY, DUSTY.
CONTRA CTOR ATTACHED.
QUALITY: FORM PROPERLY FILLED
SUPERVISOR
UP
SAFETY: SLIP, TRIP AND FALLING
HAZARD, TSL AUTHORIZ E
FINGER INJURY PERSON/ AFTER OVER HAULING EACH PART MUST BE TRAIL
5. TRAIL TAKEN
ENVIRONM ENT: NOISY, DUSTY. CONTRA CTOR TAKEN.
QUALITY: FORM PROPERLY FILLED SUPERVISOR
UP
SAFETY: FALLING HAZARD, 1. FILL GCTK TANKS WITH WATER. ENSURE NO GAS
FINGER INJURY TSL AUTHORIZ E 2. CLOSE VENT VALVE. LEAKAGE, IF HAS
WORK AFTER
ENVIRONM ENT: GASEOUS, NOISY, PERSON/ 3. OPEN GV # 004 AND GV # 005. ARREST IT.
6. OVER
AND DUSTY. CONTRA CTOR 4. OPEN ALL WATER LINE VALVE. THIS JOB DONE IN
HAULING.
QUALITY: MUST BE DONE AS PER SUPERVISOR 5. OPEN BUTTER FLY VALVE BEFORE GV # 004. ONLY SHUT DOWN
DOCUMENTS. 6. TURBINE GEAR MOTOR ENGAUGE. CONDITION.
SAFETY: NO IMPACT TSL AUTHORIZ E
7. RETURN WORK ENVIRONM ENT: NO IMPACT
PERMIT QUALITY: FORM PROPERLY FILLED
UP
PERSON/
CONTRA CTOR
SUPERVISOR
O P RETURN WORK PERMIT IN FORM

EHSMSM/WORKS/446/4001
ENSURE NO MAN POWER
THERE.
ESI ANNEXURE
ESI DOCUMENT REFERANCE NO: HBF/PSP-MECH/01/PI/ESI.00
d S
Department – H Blast Furnace (Mechanical)
Section - GCP & WWTP
a l i 1 T
Sl.
Equipment
Details
Name
EQUIP
No
Energy source
E
L
E
G
F
L
O
T
V
Type of job
Electrical
Isolation details of Energy sources & Location of Isolation Locks
Gas Fluid
Others (Gravitational / Potential /
Locomotive / EOT crane etc.)
No C Valve / Pump /
A U H
TI Panel U – Seal Valve
S I E Method Method Method Method Location
C no / Flange Location &
P
D R
A No. No.
L
Name and Design –

PREPARED BY APPROVED BY
S O
Signature with Date
NIRANJAN D. HONAP, Jr.Engg. Name and Design—SUMIT RANJAN, MANAGER
Signature with Date
l i d
Printed By -NIRANJAN HONAP(161030) Print valid till - 27-Aug-2020 Printed on - 17-Aug-2020
a SOP Valid Till - 27-Jul-2021
CONTENTS
• MECHANICAL ACTIVITIES------------------------------------------------------------------------ 04
• DAY01 ---------------------------------------------------------------------------------04
• DAY02----------------------------------------------------------------------------------------------- 12
• DAY03 ---------------------------------------------------------------------------------24
• DAY04 ---------------------------------------------------------------------------------37
• DAY05 ---------------------------------------------------------------------------------50
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• DAY06 ---------------------------------------------------------------------------------64
• DAY07----------------------------------------------------------------------------------------------- 74
S
• DAY08 ---------------------------------------------------------------------------------86
d
l i
• DAY09 ---------------------------------------------------------------------------------94
a
• DAY10 ---------------------------------------------------------------------------------105
V
• DAY11 ---------------------------------------------------------------------------------120
• DAY12----------------------------------------------------------------------------------------------- 133
• DAY13 ---------------------------------------------------------------------------------146
• DAY14 ---------------------------------------------------------------------------------158
• DAY15 ---------------------------------------------------------------------------------170
O P
• ELECTRICAL ACTIVITIES --------------------------------------------------------------------- 174
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TRT JOB
DAY1
STEP1 : CLOSING OF GV 04(IGV) & GV 05 (OGV)
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FIG. LOCAL CONTROL AND ACTUATOR
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STEP 2 : VENTING OF TRAPPED GAS WAS DONE AND THEN NITROGEN PURGING LINE
WAS OPENNED
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ROOT N2 LINE VALVE
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STEP 3 POSITIVE ISOLATION DONE AND KEYS ARE KEPT IN ISOLATION BOX
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STEP 4 :CO PPM WAS CHECKED THROUGH INTRUMENT PROTECTION BOX
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STEP 5 : COVER BOLTS WERE NUMBERED IN ORDER TO AVOID MISMATCH IN LATER
STAGES
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STEP 6: LOOSENING OF BOLTS (SPANNER SIZES USED : 65 & 75)
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STEP 7 : PLATFORM GIVEN TO APPROACH TURNING MOTOR WAS SHIFTED WITH
THE HELP OF CHAIN BLOCK SYSTEM (EOT CRANE)
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TRT JOB
DAY2
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STEP 8 : OPENNING OF FLANGE OF VENT & N2 PURGING LINE
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FIG: VENT LINE AND N2 PURGING LINE
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STEP 9: DISMANTLING /SHIFTING OF VENT AND N2 PIPELINES WITH HELP OF CHAIN
BLOCK (EOT CRANE)
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STEP 10 : CLOSING OF HYD LUBE OIL LINE VALVES USING HANDLE
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STEP 11 :PLACING OF GUIDE COLUMNS IN TURBINE CASING ( TO AVOID MISMATCH OF
TOP COVER AND BOTTOM PART OF CASING
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STEP 12 : DISMANTLING OF ALL LOOSENED BOLTS OF TURBINE CASING
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STEP 13: DISMANTLING OF DOWEL PINS (4 No.s) (SPANNER SIZE USED :85)
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STEP 14: OPENNING OF COUPLING
GUARD
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(SPANNER SIZE:18/19)
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STEP 14: OPENNING OF COUPLING
GUARD
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STEP 15: DISMANTLING OF TURNING GEAR MOTOR (SPANNER SIZE:36 (4 jack No.s) &
ALLEN KEY 27 )
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STEP 16:CARBON SEAL DISMANTLING
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CARBON SEAL CASE LNG 10MM (4 No.S) (SLOW REMOVAL REQD.)
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STEP 16: CONTD..
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CARBON SEAL IN POSITION (4No.s)
TOP: 2 SPLITS OF CARBON SEAL
BOTTOM: SPRING WHICH HOLDS
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4 SPLITS TO FORM RING
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22
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STEP 17 : JACKING BOLTS(6No.s) WERE INSERTED AND TOP COVER WAS JACKED UP
(SPANNER SIZE 85)
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TRT JOB
DAY3
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Step 18:Chain block arrangements were made to lift the cover
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STEP 19: SHIFTING OF TOP COVER (BOTH SIDE EQUAL LIFTING HAVE TO BE ACHIEVED
THROUGH CHAIN BLOCKS ADJUSTMENTS)
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STEP 20: PLACING OF TOP COVER OVER WOODEN SUPPORT
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STEP21: MEASUREMENTS OF CLEARANCES AS PER DESIGN
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Step 22: PLACING SHEETS OVER THE INLET AND OUTLET .
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STEP 23:HYD. VALVES WERE OPENED AND HYD.PUMP WAS STARTED IN ORDER TO
TAKE TRIAL OF SERVO MOTOR (FOR STATOR BLADE POSITIONING)
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STEP 24: SERVO MOTOR WAS OPERATED AND GRADUAL READING WERE NOTED
SCALE
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VIEW OF TURBINE STARTOR BLADE WITH LINK ARRANGEMENT TO SHIELD
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TSB POSITIONING BY SERVO MOTOR
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STEP25: STATOR BLADES WERE INSPECTED IN CLOSED AND FULLY OPENED CONDITION
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FOUND: 7mm
DESIGN: 0.15 - 0.3mm
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CLOSED STATE CLEARANCE MEASUREMENT BETWEEN STATOR BLADES (BY FEELER GUAGE)
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STEP25 : CONTD..
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DUST ACCUMULATION ON BLADES
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STEP 26: CLEANING OF BLADES WAS DONE
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TRT JOB
DAY4
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Step 27: FRONT BEARING COVER WAS OPENED & PLACED ON WOODEN SUPPORT
SPANNER USED : 36 (4 No.s JACK ) & ALLEN KEY 27
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COUPLING at Main oil Pump
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STEP28: TURBINE STATOR WAS SET TO FULLY OPEN FOR DISMANTLING OF MOVABLE
TOP CASE (SPANNER USED : 32/30)
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STEP 28:CONTD.
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VIEW OF MOVABLE TURBINE CASE & LINKS OF STATOR BLADES AFTER DISMANTLING
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STEP 29: DISMANTLING OF SPEED SENSOR (SPANNER USED ALLEN KEY 8)
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Step 30: Dismantling of OIL SEAL (Allen Key 16 used)
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STEP 31: JOURNAL BEARING DISMANTLED FROM BOTH THE SIDES
(SPANNERS USED 65 & allen key 16)
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EYE BOLT FIXING IN JOURNAL BEARING CASE
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STEP 31 :contd..
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STEP32: DISMANTLING OF TURNING GEAR BOLTS (BOX SPANNER :60)
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MANUAL ROTATION OF TURNING GEAR IN ORDER TO DISMANTLE THE OTHER HALF
OF TURNING GEAR VIA SLING +HOOK(EOT CRANE)
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Side jobs done
❖ Cleaning of all covers dismantled done
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❖ Dismantling of shed guards and placing of Rotor Stand
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TRT JOB
DAY5
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STEP 33: DISMANTLING OF STATIONARY TOP CASING (USING HEX HEAD OF M22 &
SPANNER 41 & 32)
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STEP34 : SHIFTING OF STATIONARY TOP CASING ( 2 NO.s M56 EYE BOLT USED)
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EQUAL LIFTING ON BOTH SIDES IS REQD TO AVOID CONTACT BETWEEN TSB
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AND TRB , SET WITH THE HELP OF CHAIN BLOCK
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STEP 34 : CONTD..
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SCALES ON STATOR BLADE
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STEP 35: FLOAT OF THRUST BEARING CHECKED AND FOUND OK(0.4 mm)
(USING 2 No.s DIAL GUAGE & 1 No. 10T Hyd. Jack)
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DIAL GUAGE ARRANGEMENT FOR FLOAT MEASUREMENT
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STEP35 : CONTD..
HYD. JACK
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THRUST BEARING
DIAL GUAGE
a l i GEAR
DIAL
V GUAGE
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STEP 36 : DIAMANTLING OF THRUST BEARING WITH RTD PROBE
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STEP 37: SHIFTING OF ROTOR OVER THE STAND (COULD’NT BE DONE USING TACKLE)
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a l i GENERATOR
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EOT CRANE UPPER LIMIT WAS TOUCHED AND STILL THE ROTOR BLADE COULDN’T
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COME OVER GENERATOR HEIGHT
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STEP 37 : contd. (DONE USING SLINGS AND CHAIN BLOCK)
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LIFTING WAS DONE SLOWLY IN ORDER TO MAINTAIN PARALLEL LIFT AT GEAR END
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STEP:37 CONTD.
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ROTOR BEING PLACED OVER STAND (WITH WOODEN SUPPORT)
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ROTOR BLADES
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DUST ACCUMULATION OVER BOTTOM HALF-STATOR BLADES
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STEP 38 : CLEANING OF LINKAGES DONE FOR FREE ROTATION OF TSB (IN PROGESS)
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TRT JOB
DAY6
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STEP 39: CLEANING OF JOURNAL BEARING (DISMANTLING OF BEARING PADS)
(ALLEN KEY :10 & 6 USED)
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STEP 40 : DYE PENETRANT TEST FOR JOURNAL BEARING ( FOUND OK)
CLEANER SOLUTION WAS

APPLIED TO THE PAD SURFACE
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PENETRAT (DYE) WAS
V
APPLIED AFTER
APPLICATION OF CLEANER
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STEP 40: CONTD..
CLEANING OF DYE WITH CLOTH
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ANALYSED AFTER APPLICATION
OF DEVELOPER
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STEP 40: CONTD..
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DYE PENETRANT SOLUTIONS(CLEANER, DEVELOPER &PENETRANT)
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STEP 41: CLEANING JOBS
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CLEANING OF GUIDE WAY OF TSB
CLEANING OF SCALES ON
BOTTOM HALF STATOR BLADES POSITIONING
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STEP 41 : CONTD..
ROTOR CLEANING
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Step 42: JACKING OF BOTTOM CASE WAS DONE USING BOX SPANNER 30 WITH
EXTENSION (2 NO.s)
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STEP 43: 4 no.s EYEBOLTS (M56) INSERTED IN BOTTOM STATOR TO LIFT IT
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LIFTING OF BOTTOM STATOR BLADES WAS INHIBITED BY JAM BETWEEN STATOR
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AND BOTTOM CASE
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STEP44 :OIL FROM BOTH BEARING SHELLS WERE TAKEN OUT
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TRT JOB
DAY7
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Step 45: JACKING OF BOTTOM STATOR WAS DONE USING HYD. JACK (PLACED WITH THE
HELP OF ROPE)
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STEP 46 : LIFTING OF BOTTOM STATOR (USING EYEBOLTS + SHACKLE + SLING)
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STEP 47 : PLACING OF BOTTOM STATOR ON FLOOR IN PROPER POSITION
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WATER ACCUMULATION ON BOTTOM COVER
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STEP 48 : DISMANTLING OF BOTTOM CASING (SPANNER 24 & ALLEN KEY 30 USED)
(M8X100mm HT BOLTSUSED)
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DISMANTLING OF GUIDE PINS USING M8X100 mm HT BOLTS
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STEP 48 : CONTD..
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STEP 49: CLEANING OF LINKAGE OF BOTTOM STATOR FOR FREE ROTATION
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STEP 50 : STATOR BLADES WHOSE FREE ROTATION COULDN’T ACHIEVED BY CLEANING
WERE OPENED AND O-RING(5mm) WAS CHANGED (SPANNER USED 46 & 30)
SPANNER 30
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STEP 50: CONTD..
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STEP 50: CONTD..
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O-RING SLOT AND O-RING
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STEP 51: CHECKING OF WATER SPRAYING NOZZLES
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TRT JOB
DAY8
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STEP 52: HOLES MADE ON BOTTOM CASING TO AVOID WATER LOGGING (4 No.s)
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STEP 53:DYE PENETRANT TEST OF BOTTOM STATOR BLADES (FOUND OK)
CLEANER PENETRANT DEVELOPER
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STEP 54: APPLICATION OF MOLYKOTE PASTE IN THE SLOT (BOTTOM CASING)
(ANTI-CORROSION )
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STEP 55 : ASSEMBLY OF BOTTOM HALF STATOR OVER BOTTOM CASING
Crank slide block • POSITIONING OF STATOR

BLADE OVER THE
CASING
• ADJUSTMENT OF SLIDE BLOCK

OF STATOR BLADES IN
ALIGNMENT WITH SLOT OF
O P BOTTOM CASING
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a l i • GRADUAL LOWERING OF
V STATOR WITH HELP OF

(CHAIN
BLOCK+EOT CRANE ) WITH
VISUAL INSPECTION
(PRECISION REQD.)
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STEP 55:CONTD..
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STEP 54: CONTD..
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PLACING OF FIXTURE OVER THE ASSEMBLY OF BOTTOM CASING & STATOR
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STEP 55: CONTD..
FIXTURE WAS
O P BOLTED UP TO
ROOT THE SLIDE
d S BLOCKS INTO THE
a l i SLOT
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TRT JOB
DAY9
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REMOVAL OF GUIDE PIN BROKEN PIECE USING MAGNETIC DRILL
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CONTD..
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STEP 56 : DEDICATED STAND WAS FABRICATED AND TOP COVER WAS PLACED OVER IT
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STEP 57 : CLEANING OF PARTING SURFACE OF TOP COVER
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STEP 58 : DYE PENETRANT TEST OF ROTOR BLADES (FOUND OK)
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STEP 59 : (BOTTOM CASING+ BOTTOM STATOR) ASSEMBLY WAS ASSEMBLED OVER THE
TURBINE BODY
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STEP 59: CONTD..
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a l i MOLYKOTE PASTE
V COATING
(Anti-Corrosion)
OVER THE RESTING
SURFACES
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STEP 59: CONTD..(ALLEN KEY 22 mm Used)
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GUIDE PINS M16 BOLTS OF GUIDE FIXTURES WERE REMOVED AFTER
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WAY OF TSB HYD. WERE PLACED PLACEMENT
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STEP 60: CLEARANCE BETWEEN BOTTOM STATOR BLADES IN CLOSED CONDITION WAS
CHECKED (AFTER POWER GETTING OF HYD. FOR TSB POSITIONING SERVO MOTOR )
CLEARANCES WERE FOUND IN

RANGE 0.12-0.5 mm
ALLOWED UPTO 2.2mm
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d S
a l i 103
STEP 61: MEASUREMENT WAS TAKEN BETWEEN THE BODY AND MOVABLE BOTTOM
CASE IN FULLY CLOSED CONDITION (TOWARDS INLET AREA)
TRYSQUARE
O P
d S
a l i
V
USE OF TRYSQUARE & INNER VERNIER FOR MEASUREMENT FOUND AS (29+2)mm
O P
d S
a l i 104
TRT JOB
P
DAY10
O
d S
a l i
V
O P
d S
a l i 105
STEP 62 :PLACING OF OIL SEAL OVER THE SEATING
APPLICATION OF HYLOMAR BLUE PASTE ON THE

SEATING OF OIL SEAL
O P
d S
a l i
V
O P
d S
Printed By -NIRANJAN HONAP(161030) Print valid till - 27-Aug-2020 Printed on - 17-Aug-2020 l i
OIL SEAL RING BOTTOM HAL1 F0 6
a SOP Valid Till - 27-Jul-2021
STEP 62: CONTD..
O P
d S
a l i
V
O P
d S
a l i 107
STEP 63: CLEANING OF JOURNAL SURFACE WITH OILSTONE
O P OIL-STONE
d S
a l i
V
O P
d S
a l i 108
STEP 64: CHECKING OF JOURNAL BEARING SEATING CONTACT
OIL PAINT
O P
d S
a l i
V
CONTACT AREA OF JOURNAL BEARING
APPLICATION OF OIL PAINT OVER THE SEATING WAS CHECKED (BLUE IMPRESSION
O P
AREA OF JOURNAL BEARING APPEARED AFTER PLACING BEARING
OVER THE SEATING) (FOUND OK)
d S
a l i 109
STEP 65 : RTD CONNECTION OF JOURNAL BEARING
O P
d S
a l i
V
O P
d S
a l i 110
STEP 66 : DYE PENETRANT TEST OF TOP STATOR BLADES
CLEANER PENETRANT DEVELOPER
PENETRANT
SPRAYING OVER
STATOR BLADES
O P
d S
a l i
V
O P
d S
a l i 111
STEP 67 : STROKE OF SERVO MOTOR FOR TSB POSITIONING CHECKED
ACTUAL
FULLY CLOSED : 28-29
FULLY OPEN : 116-
117 STROKE :88
AS PER MANUAL
O P
FULLY CLOSED:30.26
d S
FULLY OPEN:117.8
STROKE :87.8
a l i
V
O P
d S
a l i 112
STEP 68 : WATER SPRAYING NOZZLE CHECKED
O P
d S
a l i
V
O P
d S
DAMAGED GASKET
a l i 113
STEP 68 : CONTD..
O P
d S
a l i CHOKED
V NOZZLE
O P
d S
a l i 114
STEP 69: LIFTING OF ROTOR AND INSTALLING OVER THE TURBINE BODY
O P
d S
a l i
V
O P
d S
a l i 115
STEP 70 : INSTALLING OF THRUST BEARING
O P CLEANING OF THRUST PADS

WITH SRUBBER
d S
a l i
V
O P
d S
a l i 116
STEP 70: CONTD..
O P ASSEMBLING OF THRUST
d S PADS OVERBEARING
a l i
V
O P
d S
a l i 117
STEP 70: CONTD..
INSTALLING OF BOTTOM HALF

OF THRUST BEARING WITH THE
HELP OF ALLEN KEY 8mm
O P TO ROTATE THE BEARING
d S
a l i
V
O P
NOTE ALL THE THRUST PADS ARE IN BOTTOM HALF (AT EXTREME LEFT (VIEWED
FROM TURBINE END)& ATBOTTOM)
d S
a l i 118
STEP 70: CONTD..
O P
d S
a l i
V
TOP & BOTTOM HALVES HAVE TO BE ATTACHED THROUGH THE CIRCLED
O P
SLOT AND PAD (TO BE DONE PRECISION AFTER PLACING BOTH HALVES OVER
TURBINE
d S
a l i 119
TRT JOB
P
DAY11
O
d S
a l i
V
O P
d S
a l i 120
STEP 71 : CLEARING OF CHOKAGE OF NOZZLE FOUND CHOKED
O P
d S
a l i
V
(ARGON WELDING)
O P
CHECKED WITHWATER
d S
a l i
STEP 72: CHECKING OF CLEARANCE BETWEEN ROTOR & OIL SEAL (BY OIL PAINT)
O P
d S
a l i
V
O P
d S
a l i 122
STEP 73 : CHECKING OF DIFFERENT CLEARANCES WITH FEELER GUAGE
LABYRINTH AND CARRIER
O P
d S
a l i
V
BP SEAL AND CARRIER
O P
d S
a l i 123
STEP 73 : CONTD..
O P
d S
a l i
V
• STAGE 1 STATOR BLADE TO ROTOR
• STAGE 1 ROTOR BLADE TO STATOR CASING
O P
• STAGE 2 STATOR BLADE TO ROTOR
• STAGE 2 ROTOR BLADE TO STATOR CASING
d S
a l i 124
STEP 74 : MEASURING OF ROTOR TO OIL SEAL SEATING WITH INSIDE MICROMETER WITH
BOTH SIDES (FOUND OK)
O P
d S
a l i
V
O P
d S
a l i 125
STEP 75 : STAG-B PASTE APPLIED AT PARTING SURFACE OF BOTTOM STATOR HALF
BEFORE INSTALLING THE TOP STATOR HALF
O P
d S
a l i
V
O P
d S
a l i 126
STEP 76: INSTALLING OF TOP STATOR HALF
O P
d S
a l i
V PLACING OF TOP HALF STATOR OVER
BOTTOM HALF WITH PRECISION
O P
d S
a l i 127
STEP 76 : CONTD..
MOLYKOTE PASTE WAS APPLIED TO THE

BOLTS AND WERE TIGHTENED WITH THE
HELP OF SPANNER 41 & 4 No.s DOVEL
PIN WERE INSERTED
O P
d S
a l i
V
O P
LOCKING OF BOLTS DONE WITH WIRE
d S
a l i 128
STEP 77 : JOURNAL BEARING INSTALLATION (MOP SIDE)
O P
d S
a l i
V
ALLEN KEY 10 & 12 USED TO TIGHTEN THE JOURNAL BEARING TOP HALF OVER
O P
BOTTOM HALF
d S
a l i 129
STEP 78: INTERFERENCE TEST BETWEEN BEARING HOUSING AND BEARING
O P HALF
d S
a l i
V
O P
d S
a l i 130
STEP78 : CONTD..
PLACING OF SS SIM OVER THE
O P HOUSING SEATING
d S
a l i
V
O P
d S
a l i 131
STEP78 : CONTD..
PLACING OF HOUSING OVER THE

SEATING AND TIGHTENING WITH
SPANNER 65
O P
d S
a l i
MEASUREMENT OF LEAD WIRE TAKEN AFTER
V
TAKING OFF THE HOUSING
O P
d S
INTERFERENCE=SIM THICKNESS – LEAD WIRE THICKNESS (FOUND 0.02mm & 0.03mm13O2 K)
a l i
TRT JOB
P
DAY12
O
d S
a l i
V
O P
d S
a l i 133
STEP 79 :CLEARANCE CHECK OF JOURNAL BEARING
MOP side :0.4mm

Generator side :0.5
mm
Dial guage for checking lifting of housing
O P
d S Clearance between rotor & journal
a l i bearing
V Dial guage for measuring rotor lifting
Rotor was lifted with help of sling and O P

S
EOT crane hook till the journal was
d
touched
a l i 134
STEP 80: INSTALLING OF MOVABLE TOP CASING OVER TOP STATOR
O P
d S
a l i
V
INTERLOCKING OF BOLTS WITH HELP OF
O P
Spanner used :28-30 & 4 No.s of dovel pin
WIRE
d S
a l i 135
STEP 81: CLEARANCE BETWEEN TOP STATOR HALF AND 2ND STAGE ROTOR BLADE BY
FEELER GAUGE (FOUND ~ 1.8 mm)
O P
d S
a l i
V
O P
d S
a l i 136
STEP 82: CLEARANCE BETWEEN 1st STAGE TOP STATOR BLADES IN FULLY CLOSED
CONDITION BY FEELER GUAGE
O P
d S
a l i
V
O P
d S
Printed By -NIRANJAN HONAP(161030)
(FOUND 0.3 mm – 1.1 mm)
Print valid till - 27-Aug-2020 Printed on - 17-Aug-2020
a l i 137
STEP 83 : COUPLING INSTALLATION AT MOP SIDE (SPANNER 36 & Allen key: 4mm used)
O P
d S
a l i
V
O P
INSTALLING OF COUPLING ON ROTOR (ALLEN KEY 4 mm USED)
d S
a l i 138
STEP 83 : CONTD..
O P
d S
a l i
V
O P
COUPLING INSTALLATION OVER SHAFT OF MOP (MOLYKOTE SPRAY USED )
d S
a l i 139
STEP 83 : CONTD..
O P
d S
a l i
V
O P
d S
MOP LIFTED AND COUPLING HALVES WERE ENGAGED
a l i 140
STEP 84: CHECKING OF METAL-METAL GAP OF COUPLING
GAP WAS
FOUND LESS SO
GASKET OF 1.5
mm WAS
INSTALLED TO
MAINTAIN
O P PROPER GAP
d S (5-7 mm)
a l i
V GASKET
O P
d S
a l i 141
STEP 85: ALIGNMENT OF MOP SHAFT- ROTOR (DIAL GUAGE USED)
DIAL GAUGE WAS

INSTALLED ON ROTOR AND
STYLE (INDICATOR) OVER
MOP SHAFT
READING WERE TAKEN BY
O P ROTATING THE ROTOR AT

EVERY 90 DEG.
d S
a l i
V ADJUSTMENT MADE IN MOP
FIXING BOLTS AND
ALIGNMENT TOLERANCE WAS
BROUGHT 0.05 (V) & 0.5(H)
O P
d S
a l i 142
STEP 85: INSTALLATION OF TOP HALF OF OIL SEAL (ALLEN KEY 12 USED)
O P
d S
a l i
V
O P
d S
a l i 143
STEP 85 : CLEARANCE BETWEEN OIL SEAL AND ROTOR BY FEELER GAUGE
FOUND AS
O P 0.25mm
d S
a l i
V
O P
d S
a l i 144
STEP 86: INSTALLATION OF SPEED SENSOR ATMOP SIDE (ALLEN KEY 8 USED)
O P
d S
a l i
V
O P
d S
a l i 145
TRT JOB
P
DAY13
O
d S
a l i
V
O P
d S
a l i 146
STEP 87 : INSTALLATION OF CARBON SEAL BOTH SIDES
(SPANNER 18 &ALLEN KEY 10 USED)
SPRINGS WERE FIRST INSERTED INTO THE
SLOTS OF BOTTOM HALF CARBON
SEAL
OVER THE SPRING THE CARBON SEAL
BUSHES WERE INSERTED INTO THE
SLOTS (4 in no.)
O P BOTTOM HALF WAS PLACED WITH

GASKET AND BOLTED WITH SPANNER 18
d S
a l i
V
O P
d S
a l i
STEP 87 :CONTD…
FOR TOP HALF CARBON SEAL CARBON

BUSHES WERE PLACED AND SPRING
WAS PLACED OVER THE SLOT
PROVIDED ON BUSHES
O P
d S
TOP CARBON SEAL CASING WAS
a l i
THEN PLACED OVER BUSHES WITH
SPRING AND SET TO MATCH THE
V
SLOTS
AND BOLTED TO BOTTOM HALF WITH
ALLEN KEY 10
O P
d S
a l i
STEP 88 : LOCATING PIN OF MOP ( ROUND FILE USED 10mm TO SET AFTER ALIGNMENT)
O P
d S
a l i
V
O P
d S
a l i 149
STEP 89: PLACING OF CASING BOLTS (SPANNER 32 USED)
MOLYKOTE APPLICATION
OVER THE THREADS
TIGHTENED WITH HELKP OF
O P SPANNER 32 & HAMMER
d S
a l i
V
O P
d S
a l i 150
STEP 89 : APPLICATION OF STAG-B PASTE ON PARTING SURFACE (FOR SEALING)
O P
d S
a l i
V
O P
d S
a l i 151
STEP 90 : LIFTING OF TOP CASING ( EOT CRANE + 4 SLINGS + 2No.s 10T CHAIN BLOCK)
EQUAL LIFTING OF
O P BOTH SIDES WAS

DONE WITH HELP
d S OF CHAIN
a l i BLOCKS
O P
d S
a l i 152
STEP 90 : CONTD..
O P
d S
a l i
V
O P
d S
a l i 153
STEP 91 : INSTALLING OF TOP CASING (SPANNER USED : 65,75,85)
GUIDE COLUMN
POSITIONING
O P
d S
a l i
V
O P
d S
a l i 154
STEP 91: CONTD..
4 NO.s OF DOWEL
PIN WERE PLACED
(SPANNER 85)
O P
d S
a l i
V
O P
d S
a l i 155
STEP 91: CONTD..
CAP BOLTS TIGHTENING

SPANNER 65 & 75
O P
d S
a l i
V
O P
d S
a l i 156
STEP 92: PROPER LIFTING ARRANGEMENT WELDED ON PIPES
O P
d S
a l i
V
O P
d S
a l i 157
TRT JOB
P
DAY14
O
d S
a l i
V
O P
d S
a l i 158
STEP 93: INSTALLING OF BEARING GUARD AT MOP SIDE (ALLEN KEY 27mm USED)
O P
d S
a l i
V
HYLOMAR BLUE APPLICATION
O P
d S
a l i 159
STEP 94 : INSTALLING OF PIPINGS (N2 & VENT)
O P
d S
a l i
V
O P
d S
a l i 160
STEP 95: FLOAT CALCULATION OF ROTOR ( DIAL GUAGE AND HYD. JACK)
O P
d S
a l i
• DIAL GUAGE WAS SET OVER THE
V
BARRING GEAR
• JACKING WAS DONE FROM BOTH SIDES
TILL EXTREMITIES REACHED
O P
• TOTAL FLOAT : FOUND AS 0.65mm
d S
a l i 161
STEP 96: INSTALLING OF VIBRATION PROBE
O P
d S
a l i
V
O P
d S
a l i 162
STEP 97 :BOLTING UP ROTOR WITH GENERATOR AT BARRING GEAR (BOX SPANNER 60)
O P
d S
a l i
V
O P
d S
a l i 163
STEP 98:DISMANTLING OF COUPLING GUARD (BOTTOM HALF) FOR ALIGNMENT
O P
d S
a l i
V
O P
d S
a l i 164
STEP 99: ALIGNMENT CHECKED
O P
d S
a l i
V
ANGULAR MISALIGNMENT AT BOTH PLANES=0.00mm O P
PARALLEL MISALIGNMENT AT BOTH PLANES=0.02mm
d S
a l i 165
STEP 100: WORM GEAR CHECK OF TURNING GEAR MOTOR
O P
d S
a l i
V
DISENGAGED ENGAGED
O P
d S
a l i 166
STEP 100: BEARING GUARD AT GENERATOR SIDE ( ALLEN KEY 27)
LIFTING AND INSTALLING
O P
d S
a l i
V
HYLOMAR BLUE PASTE APPLICATION
O P
d S
a l i
STEP 101: COUPLING GUARD INSTALLED
O P
d S
SILICONE SEALANT APPLICATION a l i
V
O P
d S
a l i 168
STEP 102 : APPROACH TO TURNING GEAR MOTOR INSTALLED
O P
d S
a l i
V
O P
d S
a l i 169
TRT JOB
P
DAY15
O
d S
a l i
V
O P
d S
a l i 170
STEP 103 : LUBE OIL CIRCULATION STARTED
O P
d S
a l i
V
O P
d S
a l i 171
STEP 104: N2 PURGING DONE
O P
d S
a l i
V
O P
d S
a l i 172
STEP 105: IGV AND OGV OPERATED AFTER ENSURING CLOSE OF VENT VALVES
O P
d S
a l i
V
O P
d S
a l i 173
Electrical activities
O P
d S
a l i TRT-IBF
V
O P
d S
a l i 174
TRT-Transformer
At 33KV side oil leakage noticed It can be seen that the middle cable was wet
from bushing, same arrested with oil while other two cables are dry
O P
d S
a l i
V
O P
d S
a l i 175
TRT-Transformer
At two more place (cooling fins) there Primary side connection tightened
was oil leakages same arrested and temperature stickers pasted.
O P
d S
a l i
V
O P
d S
a l i 176
TRT-Transformer
Neutral switch connection tightness Neutral connection at transformer
checked. Marking done end checked.
O P
d S
a l i
V
O P
d S
a l i 177
TRT-Transformer
O P
d S
a l i
V
O P
d S
a l i 178
TRT-Generator
Generator stator connections (Located at bottom side) checked for
any heating found all tape in good condition.
O P
d S
a l i
V
O P
d S
a l i 179
TRT-GIS breaker panel
Panel open parts at back

side and front side control
section blown and cleaned.
O P
d S
a l i
V
O P
d S
a l i 179
TRT-CRP panel for GIS
Panel back side control

connections tightened,
blown and cleaned.
O P
d S
a l i
V
O P
d S
a l i 180
TRT- SPP & LSP panel
All power connections

tightened and temperature
stickers provided.
O P
d S
a l i
V
O P
d S
a l i 181
TRT-Exciter on Generator
Exicter diode chamber connection tightened and blowned.
O P
d S
a l i
V
O P
d S
a l i 182
INSTALATION OF SPEED SENSOR
*3 SPEED TRANSMITTER
• GAP SETTING IS 50 mil
(=1.27 MM)
Special procedure to measure
Gap by measuring voltage at
transmitter. ( 10 V at 1.27 mm)
O P
d S
a l i
V
O P
d S
a l i 183
THRUST BEARING PAD
Heat shrinkable tube fixing for

protection of RTD wire of
Thrust bearing Pad ,
( 1 No. pad replaced as RTD
was faulty)
O P
d S
a l i
V
O P
d S
a l i 184
Rotor Shaft Displacement Sensor
*Total Float of shaft is 0.6 mm
*Sensor is set zero, when Rotor
is at mid position i.e. 0.3 mm.
* Gap between Rotor and sensor
is set 1.27 mm by adjusting
transmitter voltage -10V
O P
d S
a l i
V
O P
d S
a l i 185

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STANDARD OPERATING PROCEDURES

Form No.: EHSMSM/446/4013 Form Rev. No.: 01 Effective date: 01/04/2009

SOP No. HBF/PSP-MECH/01/SOP-GCP-29 Effective Date 27/07/2020 REVISION No 2.02

Step Activity Associated Responsibility Process / tools / PPEs (HOW)

O P EHSMSM/WORKS/446/4001 WORK PERMIT TAKE AND

SAFETY: FALLING HAZARD,

Printed By -NIRANJAN HONAP(161030) Print valid till - 27-Aug-2020

O P RETURN WORK PERMIT IN FORM

Name and Design –

❖ Cleaning of all covers dismantled done

CLEANER SOLUTION WAS

CLEANING OF DYE WITH CLOTH

CLEANER PENETRANT DEVELOPER

Crank slide block • POSITIONING OF STATOR

• ADJUSTMENT OF SLIDE BLOCK

V STATOR WITH HELP OF

d S BLOCKS INTO THE

CLEARANCES WERE FOUND IN

APPLICATION OF HYLOMAR BLUE PASTE ON THE

CLEANER PENETRANT DEVELOPER

O P CLEANING OF THRUST PADS

INSTALLING OF BOTTOM HALF

O P TO ROTATE THE BEARING

LABYRINTH AND CARRIER

MOLYKOTE PASTE WAS APPLIED TO THE

PLACING OF SS SIM OVER THE

PLACING OF HOUSING OVER THE

MOP side :0.4mm

V Dial guage for measuring rotor lifting

Rotor was lifted with help of sling and O P

DIAL GAUGE WAS

READING WERE TAKEN BY

O P ROTATING THE ROTOR AT

O P BOTTOM HALF WAS PLACED WITH

FOR TOP HALF CARBON SEAL CARBON

TIGHTENED WITH HELKP OF

O P SPANNER 32 & HAMMER

O P BOTH SIDES WAS

CAP BOLTS TIGHTENING

LIFTING AND INSTALLING

Panel open parts at back

Panel back side control

All power connections

Heat shrinkable tube fixing for

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