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STEAM TURBINE 500 MW (KWU DESIGN)
DOCUMENT NO. TS-T1-08
Bharat Heavy Electricals Limited
POWER SECTOR TECHNICAL SERVICES (HQ)
Bharat Heavy Electricals Limited Rev 00, 7-98
T1-08-0801G Page No. 1
I am glad that Power Sector - Technical Services ( Head Quarters), Noida has brought out this erection manual of 500 MW steam turbine (KWU design) being produced by BHEL. This manual lays emphasis on site optimisation techniques which aims at uniform erection practices, improvement in quality, reduction in time cycle and saving in cost.
I am sure, this manual will form the basis for site erection activities so that the organisation can derive full benefit out of this. It is needless to emphasize that upgrading of technology is a continuous process and we have to review our methods of working and make suitable changes, wherever required.
(K P Mathur) Executive Director (PEM & TS)
Bharat Heavy Electricals Limited Rev 00, 7-98
T1-08-0801G Page No. 2
The Erection Manual for 500 MW Steam Turbine (KWU design) manufactured by BHEL for Thermal Power Stations has been prepared by a team of BHEL engineers having long experience in Erection & Commissioning, Design, Quality control of steam turbines. This dedicated team has been drawn from regional erection group, designed department of manufacturing units, PS-Q & TS-HQ, Noida. The manual carries general description of steam turbine, erection procedure, special instruction, general instructions, and various other technical instructions with an intention to establish an uniform approach for erection of steam turbine. The Erection Manual provides broad based guide line for erection of steam turbine. Product standard, technical circulars & BHEL drawings for the specific project will precede the instructions and guidelines furnished in this manual. Project specific document will be generated by region concerned. This document is generated as a standard Erection Manual for 500 MW fixed pedestal type steam turbine with spring loaded foundation. The work done by TASK FORCE is commendable. Feed-back and suggestions are welcome for the improvement of this Erection Manual to bringing down the cycle time with quality. BHEL reserves the right to suggest alternative necessity arises at site due to local site conditions . procedure if
(BABOO RAM) GENERAL MANAGER(TS&Q)
Bharat Heavy Electricals Limited Rev 00, 7-98
T1-08-0801G Page No. 3
4 .08-0909G T 1-08-1010G T 1-08-1111G T 1-08-1212G T1-08-1313 G Bharat Heavy Electricals Limited Rev 00. 7-98 T1-08-0801G Page No.1 2 3 4 5 6 7 8 9 10 11 12 13 TECHNICAL DATA INSTRUCTION FOR HANDLING AND STORAGE OF TURBINE ERECTION SEQUENCE ERECTION PROCEDURE GROUTING PROCEDURE ASSEMBLY OF IP MODULE AT SITE SEALING AND ANTISEIZING COMPOUNDS CRITICAL ACTIVITIES SPRING LOADED FOUNDATION ERECTION OF PIPING SPECIFICATION FOR GAS HEATING DEVICE SPECIFICATION FOR BREECH NUT HEATING DEVICE SPECIFICATION FOR THERMAL INSULATION T 1.08-0505G T 1-08-0606G T 1-08-0707G T 1-08-0808G T 1.08-0101G T 1-08-0202G T 1-08-0303G T 1-08-0404G T 1.
Generator Generator Aux Power Plant Piping C&I 1.1 PRODUCT CODE B BA T TA G GA P CI Boiler Boiler Aux. 7-98 . 5 Bharat Heavy Electricals Limited Rev 00. XX Alpha X Numeric XX Numeric XX Numeric XX X Numeric Alpha Type of Instruction System Instruction No System Designation Rating of Main Equipment Type of Manual Product Code 1. Turbine Turbine Aux.The following codification system is used for numbering of instructions and the codification of Log Sheets is as per FQA document.2 TYPE OF MANUAL 1 2 3 Erection Commissioning Service T1-08-0801G Page No.
7-98 T1-08-0801G Page No. 6 .3 RATING OF MAIN EQUIPMENT 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 200/210 MW 120 MW 110 MW 60 MW 30 MW 100 MW 235 MW 500 MW 210 MW 120 MW 60 MW 70 MW Industrial Units 210 MW 210 MW 500 MW 250 MW CCP Tower Type Concrete Pylem Tower Type Steel Structure Tower Type Once through KWU Design KWU Design KWU Design KWU Design KWU Design Bharat Heavy Electricals Limited Rev 00.1.
4. 5. 9. 7. 7-98 T1-08-0801G Page No.4 SYSTEM DESIGNATION SNO 1. 12. 10. 13.5 TYPE OF INSTRUCTION G T L C General Technical Log Sheet Check List Bharat Heavy Electricals Limited Rev 00. 8. 6. 7 .1. 2. 11. DESCRIPTION TECHNICAL DATA INSTRUCTION FOR HANDLING AND STORAGE OF TURBINE ERECTION SEQUENCE ERECTION PROCEDURE GROUTING PROCEDURE ASSEMBLY OF IP MODULE AT SITE SEALING AND ANTISEIZING COMPOUNDS CRITICAL ACTIVITIES SPRING LOADED FOUNDATION ERECTION OF PIPING SPECIFICATION FOR GAS HEATING DEVICE SPECIFICATION FOR BREECH NUT HEATING DEVICE SPECIFICATION FOR THERMAL INSULATION 1. 3.
LOAD RATED MAX.TIRUCHY DN-320 TYPE TYPE TYPE MAKE EXTRACTION SWING CHECK VALVES : EXTRACTION-1 EXTRACTION-2 EXTRACTION-3 : NO VALVE : 1 SWING CHECK VALVE WITH ACTUATOR : 1 SWING CHECK VALVE WITH ACTUATOR & 1 SWING CHECK VALVE WITHOUT ACTUATOR : 2 SWING CHECK VALVE WITH ACTUATOR : 2 SWING CHECK VALVE WITH ACTUATOR : 1 SWING CHECK VALVE WITH ACTUATOR & 1 SWING CHECK VALVE WITHOUT ACTUATOR MAKE MAKE DN-800 BHEL.TIRUCHY DN-500 BHEL.2 EXTRACTION-5 MAKE MAKE MAKE DN-500 BHEL.TIRUCHY EXTRACTION-6 : NO VALVE SPEED RATED SPEED 50. UNDER VALVE WIDE OPEN (VWO) CONDITION 500 MW 524.0 /S Bharat Heavy Electricals Limited Rev 00. 8 .TIRUCHY EXTRACTION-4.1 EXTRACTION-4.2 CONSTRUCTION THREE CYLINDER REHEAT CONDENSING TURBINE SINGLE FLOW HP TURBINE WITH 17 REACTION STAGES DOUBLE FLOW IP TURBINE WITH 12 REACTION STAGES PER FLOW DOUBLE FLOW LP TURBINE WITH 6 REACTION STAGES PER FLOW 2 MAIN STOP AND CONTROL VALVES 2 REHEAT STOP AND CONTROL VALVES 1 SWING CHECK VALVE IN COLD REHEAT LINE 2 BYPASS STOP AND CONTROL VALVES TYPE TYPE 500 MW H30-100-2 M30-63 N30-2X10 EV320-1 IV560 DN-800 BHEL.TIRUCHY DN-500 BHEL. 7-98 T1-08-0801G Page No.TIRUCHY DN-400 BHEL.
9 17.2 1.2 8.58 1. SPEED.2 1.2 8.41 0. THE AGGREGATE DURATION OF SUCH SWINGS MUST NOT EXCEED 12 HOURS IN ANY ONE YEAR.4 44.3 BAR BAR BAR BAR BAR BAR BAR BAR BAR BAR BAR * THESE VALUES CORRESPOND TO 500 MW LOAD WITH 3% MAKE-UP AND 0.2 2. ALL PRESSURES ARE ABSOLUTE PRESSURES Bharat Heavy Electricals Limited Rev 00. SPEED.SPEED LIMITATION IN LOAD & STATION AUX.9 40.5 /S 51. 9 . 7-98 T1-08-0801G Page No.7 163. 55.4 22.329 0.5 /S 47.7 154.7 TO 47.7 3. PERMISSIBLE WITHOUT TIME LIMIT.4 52.66 0.41 0.3 SHORT TIME OPERATION 20.5 7.7 169.257 0.5 /S MAX.1013 LONG TIME OPERATION 166. LONG TIME OPERATION : UPPER LIMIT VALUE. DURING THE LIFE OF LP BLADING SPEED BELOW SPEED ABOVE SPEED EXECUTION RANGE AT OPERATION WITHOUT LOAD* STANDARD OVER SPEED TRIP SETTING * THIS SPEED RANGE SHOULD BE PASSED THROUGH IN ONE SMOOTH OPERATION TO AVOID ENDANGERING THE BLADES DUE TO RESONANCE : : : : 524. LOAD OPERATION MAX.2 51.5 /s STEAM PRESSURES RATED* INITIAL STEAM BEFORE 1st HP DRUM STAGE HP CYLINDER EXHAUST IP CYLINDER STOP VALVE INLET EXTRACTION 6 EXTRACTION 5 EXTRACTION 4 EXTRACTION 3 EXTRACTION 2 EXTRACTION 1 LP CYLINDER EXHAUST 166. NO TIME LIMITATION PERMISSIBLE FOR A MAXIMUM OF 2 HRS.7 3. SHORT TIME OPERATION : PERMISSIBLE MOMENTARY VALUE.66 0.5 TO 60 /S : : 6.2** 57.9 57.1013 BAR BACK PRESSURE WITH ALL HEATERS IN SERVICE AND RATED STEAM CONDITIONS.7 52.4** 55. ** THE SAFETY VALVES MUST BE SET SO THAT THESE SHORT TIME VALUES ARE NOT EXCEEDED.5 /S 47.0 46.3 44.0 22. NO TIME LIMITATION MIN.
5 mm TRIP * 1 mm * DIRECTION OF ROTATION ANTI CLOCK WISE WHEN VIEWED FROM FRONT PEDESTAL TOWARDS THE GENERATOR Bharat Heavy Electricals Limited Rev 00.3 0.3 0. 7-98 T1-08-0801G Page No.LOW VACUUM TRIP.6 BAR BAR BAR SEAL STEAM SUPPLY SYSTEM PRESSURE IN SEAL STEAM HEADER (ABOVE ATMOSPHERIC) : 35 MBAR AXIAL SHIFT ALARM * 0. 10 . STANDARD SETTING HYDRAULIC LOW VACUUM TRIP ELECTRICAL LOW VACUUM TRIP HYDRAULIC LOW VACUUM TRIP BYPASS OPERATION : : : 0.
0 421.STEAM TEMPERATURES RATED VAL.3 400 h PER ANNUM 80 h PER ANNUM MAX.0 O O 552.3 184.0 413.3 86. ONLY VALID FOR THE NO LOAD PERIOD WITH HIGH REHEAT PRESSURE AFTER TRIP-OUT FROM FULL LOAD OPERATION.9 292.O 552.5 70.4 242.5 70.3 139.3 136.0 536. * THESE VALUES CORRESPOND TO 500 MW LOAD WITH 3% MAKE-UP AND 0. 15 MINUTES THE TURBINE IS IMMEDIATELY RE-LOADED OR THE BOILER IMMEDIATELY REDUCED TO MINIMUM LOAD IF NO LOAD OPERATION IS MAINTAINED. FOR INDIVIDUAL CASE APPROX. 15 MIN IN INDIVIDUA L CASE 566.0 459.1013 BAR BACK PRESSURE WITH ALL HEATERS IN SERVICE AND RATED STEAM CONDITIONS.0 LONG TIME VALUE (WITHIN ANNUAL MEAN VAL.) 546.O 546.1 187.0 C C RATED VALVE * LONG TIME OPERATI ON 80 h PER ANNUM MAX.3 66.0 360.3 128. PERMISSIBLE WITHOUT TIME LIMIT. ANNUAL MEAN VALUE INITIAL STEAM IP CYLINDER STOP VALVE INLET 536. 15 MIN IN INDIVIDU AL CASE 440.0** O O O O O O O O HP CYLINDER EXHAUST EXTRACTION 6 EXTRACTION 5 EXTRACTION 4 EXTRACTION 3 EXTRACTION 2 EXTRACTION 1 LP CYLINDER EXHAUST 340.0 440.0 C C C C C C C C LONG TIME OPERATION : UPPER LIMIT VALUE.0 IN SPECIAL CASES AT NO LOAD 500. ** Bharat Heavy Electricals Limited Rev 00.0 566.9 304.5 46.0 340.9 346.0** 500.1 195.1 360. 7-98 T1-08-0801G Page No. 11 .
SPRAY WATER TO LP TURBINE MUST BE SWITCHED ON AT 90 C. TO PREVENT HEAT-UP BEYOND PERMISSIBLE TEMPERATURES. MOTORING MUST NOT BE ALLOWED TO CONTINUE FOR LONGER THAN ONE MINUTE. CERTAIN TURBINE COMPONENTS ARE HEATED UP BY WINDAGE POWER IN THE BLADING. 12 . 7-98 T1-08-0801G Page No. MIDDLE LP TURBINE.) : 28 C IN THE HOTTEST LINE THE LIMITATIONS INDICATED FOR INITIAL STEAM & REHEAT TEMP. REAR ALARM AT * 90 * 30 * 30 MACHINE MUST BE SHUT DOWN AT * 100 * 45 * 45 O C C C O O FEEDWATER HEATER OUT OF SERVICE OPERATION WITH FEEDWATER HEATER OUT OF SERVICE EXTRACTION A6 = 0 EXTRACTION A5 = 0 EXTRACTION A3 = 0 EXTRACTION A2 = 0 EXTRACTION A1 = 0 EXTRACTION A6. BETWEEN PARALLEL STEAM SUPPLY LINES : • • NO TIME LIMITATION : 17 C O O SHORT TIME PERIOD (15 MIN.500 MW MW MOTORING : MOTORING IS THE CONDITION IN WHICH THE TURBINE IS DRIVEN BY THE GENERATOR AT RATED SPEED WITH THE STOP & CONTROL VALVES CLOSED. FRONT LP TURBINE.CASING TEMPERATURES WALL TEMPERATURES HP TURBINE CASING EXHAUST OUTER CASING OF LP CYLINDER ALARM AT 480 90 MACHINE MUST BE SHUT DOWN AT 500 110 O O C C PERMISSIBLE DIFFERENTIAL TEMP. MUST NOT BE EXCEEDED. O TEMPERATURES DIFFERENCE DIFFERENCE BETWEEN UPPER & LOWER CASING HALVES HP TURBINE. A5 = 0 MAIN STEAM FLOW Kg/s 395 421 423 425 423 400 LOAD MW 500 500 500 500 500 525 OUTPUT LIMIT DURING TESTING WITH AUTOMATIC TURBINE TESTER TESTING OF MAIN STEAM STOP & CONTROL VALVE TESTING OF HRH STEAM STOP & CONTROL VALVE 400 200 . Bharat Heavy Electricals Limited Rev 00.3 BAR IS EXCEEDED. IN THIS OPERATING MODE. MOTORING MUST NOT BE ALLOWED TO CONTINUE FOR MORE THAN 4 SECONDS. IF THE CONDENSER LOW VACUUM LIMIT OF 0.
8 20. COMPLETE WITH SERVO MOTORS.1 85. Bharat Heavy Electricals Limited Rev 00. COMPLETELY ASSEMBLED IP TURBINE. 13 . WEIGHTS HP TURBINE. COMPLETE WITH BLADING LP TURBINE ROTOR.7 15.5 16. TOP HALF OUTER CASING COMPLETE LP CYLINDER. TOP HALF OUTER CASING IP TURBINE. COMPLETE WITH BLADING LP TURBINE.9 32. WITHOUT BEND & PIPE SECTION ALL WEIGHTS HAVE BEEN CALCULATED WITH SAFETY ALLOWANCES. COMPLETE WITH SERVO MOTORS. 7-98 T1-08-0801G Page No.BEARING TEMPERATURES ALARM AT OPERATION TEMPERATURE BELOW 75 OC OPERATION TEMPERATURE 75 TO 85 OC OPERATION TEMPERATURE 85 TO 90OC OPERATION TEMPERATURE ABOVE 90OC 90 100 110 115 MACHINE MUST BE SHUT DOWN AT 120 120 120 120 O O O O C C C C VIBRATION ABSOLUTE BEARING HOUSING VIBRATION STANDARD ALARM SETTING MAXIMUM ALARM SETTING LIMIT VALUE FOR TRIPPING 35 45 ABSOLUTE SHAFT VIBRATION 30 µ m ABOVE NORMAL LEVEL* 120 200 µm µm µm * THE NORMAL LEVEL IS REPRODUCIBLE VIBRATIONAL BEHAVIOUR TYPICAL FOR THE MACHINE AND DEPENDENT ON THE OPERATING CONDITIONS. WITHOUT BEND & PIPE SECTION REHEAT STOP & CONTROL VALVE. TOP HALF INNER CASING.3 23. COMPLETE WITH BLADING MAIN STOP & CONTROL VALVE. VIBRATION READINGS INDICATED IN CONTROL ROOM ARE HALF PEAK. COMPLETE WITH BLADING. SLINGS CHOSEN MUST PROVIDE SUFFICIENT SECURITY. THE ABOVE VALUES ARE ALSO GIVEN IN HALF PEAK.6 25.5 42. STATIONARY BLADE CARRIERS & DIFFUSER : : : : : : : : : : 94. COMPLETE WITH BLADING IP TURBINE ROTOR.2 T T T T T T T T T T HP TURBINE ROTOR. TOP HALF OUTER SHELL OF INNER CASING.6 38.
SETTING 1 DUPLEX OIL FILTER FOR JACKING OIL FILTRATION PARTICLE SIZE OF JACKING OIL FILTER : : : : : : : : : : : : : : : 0. NUMBER OIL TEMP.2. TEMP. SETTING MAX. M Cu . FRONT PEDESTAL) BEARING 2 BEARING 3 BEARING 4 GENERATOR FRONT BEARING GENERATOR REAR BEARING EXCITER BEARING 1 DUPLEX OIL FILTER FOR BEARING OIL (FULL FLOW) DUPLEX OIL FILTER .62. RISE OF OIL IN BEARINGS NORMAL MAX. UNIT SHUT DOWN MAX.9. SIZE 355/750.OIL SUPPLY MAIN OIL TANK. AT COOLER OUTLET.70 200 dm3/S dm3/S dm3/S dm3/S dm3/S dm3/S dm3/S mm BOLL & KIRCH 37 250 200 100 25 37 µm µm BAR BAR mm µm Bharat Heavy Electricals Limited Rev 00. NORMAL MAX.6 7. 7-98 T1-08-0801G Page No.5 28. AT COOLER OUTLET. NUMBER OIL COOLER FOR RESERVE. PRESSURE LIMITING VALVE IN JACKING OIL SYSTEM. RATED CAPACITY Ist OIL FILLING (ESTIMATED) FLUSHING OIL QUANTITY (ESTIMATED) OIL COOLER FOR OPERATION.5 1 I 38 45 47 75 20 25 Cu .8 15. M NO. OIL TEMP.1 8. 14 . NO.92 7. : : : : : : : : : : : 25/40 47.92 0. M Cu . O C O C C O ESTIMATED OIL REQUIREMENTS OF BEARINGS : BEARING 1(HP TURBINE. UNIT IN OPERATION MIN. MAKE FILTRATION PARTICLE SIZE OF DUPLEX FILTER ELEMENT FILTRATION PARTICLE SIZE OF MAIN OIL TANK FILTER ELEMENT SAFETY VALVE IN JACKING OIL SYSTEM.4 4. TYPE .
3 DC MOTOR 49.6 AUXILIARY OIL PUMP 2 KSB ETA-15050VVL 89.42 AC MOTOR DC MOTOR /s Bharat Heavy Electricals Limited Rev 00.25 6.53 178 dm3/s BAR 50 TURBINE 24.75 AC MOTOR 24. 15 .OIL PUMPS MAIN OIL PUMP QUANTITY MAKER TYPE CAPACITY (RATED) DISCHARGE PRESSURE (GAUGE) SPEED DRIVE 1 BHEL 97.22 dm3/S 75 8. 7-98 T1-08-0801G Page No.3 JACKING OIL PUMP AC : 2 DC : 1 TUSHAKO SDF80 1.2 DC EMERGENCY OIL PUMP 1 KSB ETA-10033VVL 30 2.
Bharat Heavy Electricals Limited Rev 00.28 3. RATED CAPACITY Ist FLUID FILLING (ESTIMATED) FLUSHING FLUID QUANTITY (ESTIMATED) CONTROL FLUID COOLER FOR OPERATION.CONTROL FLUID SUPPLY CONTROL FLUID TANK. CONTROL FLUID MAINTENANCE EQUIPMENT : GEAR PUMP MANUFACTURER TYPE FLUID FLOW GAUGE PRESSURE SPEED MOTOR POWER 2 EARTH FILTERS MANUFACTURER TYPE EARTH FILLING MESH 1 FINE MESH FILTER MANUFACTURER TYPE FILTRATION PARTICLE SIZE FILTER MATERIAL CONTROL FLUID SUPPLY SYSTEM A FIRE RESISTANT FLUID IS USED FOR THE CONTROL SYSTEM : : : : : : : : : : : : : STEIMEL BGK 2-24R 0.75 ROTRING PYG5-350 140 Kg dm3/S at S-1 KW ROTRING S-1800-14-TUY 3-5 COTTON µm SCOPE The document covers all steam turbine components and provides the handling. M Cu . 7-98 T1-08-0801G Page No. NUMBER : : : : : 10/16 15 10 1 I Cu .06 25 0. 16 . M Cu . A strict adherence to these instructions is necessary to avoid damages during handling and storage at site. NO. inspection and storage instructions for large steam turbine components at site. M NO. NUMBER CONTROL FLUID COOLER FOR RESERVE.
5 M above the tallest object. If the rigger/operator is not sure of the weight of the item/package (load) to be handled. since even the slightest negligence and non observance of the rules may result in accidents. turn buckles. are marked on the packages and on the drawings. While lifting/handling these packages/equipment. The work related to handling of the loads (packages or equipment) by crane or by other hoisting mechanism should be entrusted to trained riggers only. The rigger and the crane operator should see that the hook and the ropes of the crane occupy vertical position. 7-98 T1-08-0801G Page No. on the path of the load. Bharat Heavy Electricals Limited Rev 00. If it is necessary to rearrange the sling lengths. The center of gravity of the load should be aligned with the vertical axis of the crane hook. Before using them. The eye bolts. he must ask for the required information before handling the equipment. the rigger must check and ensure that there are no loose parts or tools on the load. and wire ropes of suitable sizes should only be used for handling of the equipment. These devices. after use. they should be thoroughly inspected to their full threads. Dragging of the load by slanting ropes is not allowed. Before giving a signal to lift the load. so as to avoid any chance of slipping then the load comes on them. which may cause damage to equipment or injury to men. The site for the rigging work involving lifting and conveying of loads should be well lighted. Before horizontal conveyance of the load the rigger must see that the load has been lifted to a height at least 0. The positions where the slings are to be put. which might fall during lifting. The slings of the proper sizes and lengths should only be used for handling the equipment/packages. the load must be lowered and then the slings rearranged. The loads must not be lifted unless the crane operator can see clearly the signals given by the rigger. 'D' shackles. they should be thoroughly inspected. The use of these lifting devices facilitates correct slinging and maintain horizontal position of the components. The turbine rotors and cylinder covers (in assembled condition are lifted by the use of special lifting devices supplied by BHEL. Before using. before hoisting the load.HANDLING OF EQUIPMENT : In any kind of rigging work it is necessary to strictly observe the safety precautions. Then the load must be lifted 100 or 200 mm high for checking the uniformity of sling tensioning and reliability of lashing. 17 . should be properly stored and conserved so as to ensure that they do not get damaged during storage. The angle between the two arms of the sling at the crane hook should be small (depending upon the dia of the sling) so as to have proper loading of the sling. the slings should only be put at the proper places.
for which the provision of threads holes have been made in the diaphragms. it is prohibited to put the sling across the rabbit surface of the bearings. While handling LP rotor with free standing blades.001 to facilitate storage and handling of the crates and protection of equipment inside. slings must be inspected and tested. properly conserved after use and periodically In the turbines having diaphragms. INSPECTION Before storing the equipment it should be opened for visual examination or the internal packing. 18 Bharat Heavy Electricals Limited Rev 00. It is necessary to carryout first inspection within three weeks of arrival of the consignment. in addition to the end supports. all the equipment should be inspected once in every three months to insure that the conservation is intact. For handling the welded diaphragms. few extra supports at the intermediate positions must be provided.While the load is being conveyed. the inspection should be done once in a month. If any one of the personnel present during lifting or lowering of the load detects some defect of the crane or sling of notices some conditions jeopardizing the lifting or lowering operation. Threaded holes have been provided. While handling the bearings. When they are placed on the floor. protective coating and condition of the equipment. While handling the cylinders. should be done with extra care. During rainy season. it must be ensured that the slings or any other material does not get rubbed at their horizontal and vertical parting planes or at any other machined surface. Thereafter. he must give a signal for emergency grounding of the package or components. Prior to lowering the load the rigger should examine the ground on which the load will be. care must be taken to ensure that no force is exerted on the free standing blades to avoid collapsing of clamping pieces under blade root. Any damage to packing and conservation should be immediately rectified. it is prohibited to handle diaphragms by putting slings in between the blades. endwall etc. All lifting devices. MARKINGS ON PACKING CASES Various symbols are marked on the packing cases as per 0456. Smooth lifting and transportation of equipment must be ensured. 7-98 . the rigger must accompany it and see that it is not moved above any person. At any time. special lifting devices is supplied by BHEL and the cast diaphragms are handled by putting the eye bolts. Shocks and jerks should be avoided. lowered and make sure that these is no risk of falling or slipping of the load. The handling of the long components such as longitudinal girder. in which the eye bolts have to be put for handling of the bearings. if any original T1-08-0801G Page No.
+50 C to 500 C upto 500 C RELATIVE HUMIDITY < 70 % ARRANGEMENT Totally enclosed. 7-98 T1-08-0801G Page No. In case of slightest sign of pitting on the journals and thrust collar. 19 . STORAGE All steam turbine equipment should be accommodated in the designated place of storage immediately after arrival at destination. it should be reconserved as per conservation instructions No. This is very essential particularly during the rainy season.conservation is found damaged. ventilated and dry with cemented floor. rain proof. relevant While inspecting the packages containing rotors. Roofed area with walls (of brick / asbestos/ GI sheet ) around and cemented / pucca hard floor. immediate steps for rectification should be taken and equipment reconserved as per relevant conservation instructions. special care should be taken to check the journals. Raised platform with shed of asbestos / GI sheet / water proof tarapaulin. Raised Platform. ST 33004. 'Q' - 'R' 'S' - Bharat Heavy Electricals Limited Rev 00. Store houses fall into the following categories TYPE OF STORE HOUSE 'P' CONDITIONS TEMP.
Packages upto 5 tones can be placed on upon the other upto 2. lighter packages would be laid upon heavier once to avoid any damage to lower packages. so as to avoid sagging during storage. Small and medium size parts can be kept on shelves with proper identification tags. the roof/walls may be constructed/fabricated after placement of the component on cemented/pucca hard floor. The long packages should be supported at intermediate places also. Bharat Heavy Electricals Limited Rev 00. Level should be maintained for all the packages and equipment and should be uniformly supported to avoid distortion. Complete storage area especially the ‘R’ & ‘S’ catagory must be adequately fenced & protected against theft & pilferage. 20 . For heavier components under ‘Q’.The platforms and store-houses should be built up in conformity with the fire prevention rules and standards. Store houses should preferably be equipped with proper lifting devices to ensure normal handling of equipment. surface and rain water. In doing so.5m in height using required number of wooden spacers 50 mm thick. These store houses and areas around them should have proper drainage facility for the sub-soil. Articles weighing more than 5 tones should be laid in a single tier. Store house should be provided with proper ventilation facilities. The water should not be allowed to stand or get accumulated in these areas. especially where the material has been stored. 7-98 T1-08-0801G Page No.
DESCRIPTION OF THE COMPONENT FOUNDATION BOLT EMBEDDED PARTS (ADDITIONAL) COMPONENTS OF BASE PLATE ASSLY. 28. 19. 23. 6. 17. 3. 22. 25. 29. 13. 21. 26. 10. 8. 2. 14. 9. 15. 27. 12. 24. 30. 21 Bharat Heavy Electricals Limited Rev 00.STORAGE OF STEAM TURBINE COMPONENTS SNO. 7-98 . 18. 5. PEDESTAL BEARING PEDESTAL PARTS FRONT BEARING PEDESTAL LIFTING BEAM LP CASING EXTRACTION A1 LP EXTRACTION A2 LP EXTRACTION A3 LP EXTRACTION PIPE SHEATHING INNER GUIDE PLATE DIFFUSER DIFFUSER (UPPER & LOWER HALVES) LP INNER-OUTER CASING (VH) LP INNER CASING ASSEMBLY (LH & VH) HEATING DEVICE LP CASING ASSEMBLY LP INNER CASING ASSEMBLY (FASTENER) INNER GUIDE PLATE DIFFUSER (GS) LP ROTOR IP TURBINE TYPE OF STORAGE 1. 4. 16. 11. 20. BASE PLATE LP CASING LP OUTER CASIONG LONGITUDINAL GIRDER (LEFT & RIGHT) LP FRONT WALL (TS&GS) LP SHAFT SEALING (FRONT & REAR) AUXILIARIES OF TURBINE HP/IP BEARING PEDESTAL HP/IP BEARING PEDESTAL ASSEMBLY PARTS IP/LP PEDESTAL ASSEMBLY LP/GEN. 7. Q R Q R R R R Q Q Q Q Q Q Q Q R R R R R R R Q Q Q Q Q R Q Q T1-08-0801G Page No.
38. 50. 37. 53. 57. IP TURBINE PARTS IP INLET PIPES HP TURBINE HP INLET ASSEMBLY HP EXHAUST ELBOW HPT RELATED PARTS FRAME FOR SUSPENSION (ESV) SUSPENSION OF VALVE (ESV) ESV & CV CASING WITH VALVE ESV SERVOMOTORS WITH LIMIT SWITCH HP CONTROL VALVE SERVOMOTORS SUSPENSION OF VALVE (IV) IV & CV CASING WITH VALVE IV SERVOMOTORS WITH LIMIT SWITCH IP CONTROL VALVE SERVOMOTORS FRAME FOR SUSPENSION (IV) IV SERVOMOTORS WITH LIMIT SWITCH STEAM BLOWING & HYD. 56. 62. 32. 36. FOR SUCTION PIPE NB 300 MAIN OIL TANK MAIN OIL TANK & NOZZLE ASSEMBLY OIL STRAINER LEVEL MONITOR INSTALLATION INSTRUMENTS LEAKAGE / DIRTY FLUID TANK VARIABLE ORIFICES & THROTTLE Q Q Q Q Q Q R Q Q Q Q Q Q Q Q R Q Q Q Q Q q Q Q R R R R Q Q Q R Q T1-08-0801G Page No. 60. 44. 34. 45.31. 55. 52. 49. 7-98 . 41. 43. 33. 51. 58. 54. 40. 46. 39. 48. 22 Bharat Heavy Electricals Limited Rev 00. 42. 61. 59. 63. FOR SUCTION PIPE NB 350 INJR. 35. 47. TEST DEVICE TOOLS FOR GOVERNING SYSTEM SUSPENSION OF LPB VALVE WATER INJECTION VALVES CHEST LPB WITH STOP & CONTROL VALVE LPB STOP VALVE SERVOMOTOR LPB CONTROL VALVES SERVOMOTORS INJR.
74. TRANSMITTERS BAR. DAMPING DEVICES CROSS AROUND PIPE SUPPORT FOR CAP CHANGE OVER VALVE RATING & MONOGRAM PLATES OIL STRIPER HOUSING FOR HRH STEAM STRAINER HOUSING FOR MAIN STEAM STRAINER MS & HRH STR. 73. 72. 81. 79.HSG GASKET STEAM STRAINER MS STEAM STRAINER HRH COMPENSATOR TURBINE CONTROL LPB / SUPPLY RACK TEMPERATURE & PRESSURE CONNECTIONS PR. 71. 78. 70. 65. 67. 7-98 T1-08-0801G Page No. 66. 68. PROBES THERMOCOUPLES TRANSMITTERS & JUNCTION BOXES R R R Q R R R Q R R R Q Q Q Q Q Q Q Q Bharat Heavy Electricals Limited Rev 00. 80. 82.64. 76. 75. 23 . CONTROL FLUID TANK CONTROL FLUID TANK NOZZLE ARRANGEMENT EXPANSION TANK FILTER & PR. 69. 77.
28. SEAL OIL UNIT HYDROGEN DISTRIBUTION CARBON DIOXIDE DISTRIBUTION VALVES FOR AUXILIARY SYSTEMS GAS UNITS FLEXIBLE LEADS TYPE OF STORAGE 1. 13. 22. GEN VVIEW HEADER ASSEMBLY TERMINAL BUSHING AND HEADER ASSEMBLY BEARING WITH BRUSH GEAR SEAL BODY TEMP. 11. 9. EXPANSION TANK OIL SEPARATOR PRE CHAMBER S. 32. 10. 5. 25.T. 26. 18. 14. 2. 7-98 T1-08-0801G Page No. 27. 7.P. CONNECTION CASING FOR TURNIONS ERECTION MATERIALS ERECTION DEVICES SHAFT SEALS SEAL RINGS ADOPTING RING AUXILIARY BEARING CENTRIFUGAL FAN CARBON DIOXIDE VAPOURISER FILTER O. 4.C. 29. 30. R R Q Q Q R Q R Q Q Q Q R Q R Q Q Q Q Q Q Q R R R R Q R R P Q Q STORAGE & PRESERVATION OF COMPONENTS OF HEAT EXCHANGERS SNO. EXCITER AND SYSTEMS SNO. 24. 31. 3. 21. 6. 24 .STORAGE & PRESERVATION OF COMPONENTS OF TURBOGENERATOR. 17. 20.O. DESCRIPTION OF THE COMPONENT EMBEDDED PARTS FOUNDATION PARTS WOUND STATOR WITH GAS COOLERS TURNION FOOT PLATES ROTOR ASSEMBLY OF PIPE CONTROL FOR GAS COOLERS END SHIELDS FAN SHIELD. 8. 23. 16. DESCRIPTION OF THE COMPONENT TYPE OF STORAGE PRODUCT : CONDENSER Bharat Heavy Electricals Limited Rev 00. 12. 19.S. 15.
25 . 4. BOTTOM PLATE LOWER DOM WALL SIDE WALL WATER CHAMBER UPPER DOM WALL STIFFENING PIPES STIFFENING RODS TUBE SUPPORT PLATE WATER BOX AIR EXTRACTION PIPING HOTWELL SPRING ELEMENTS LOOSE ITEMS INSTRUMENTS CONDENSER TUBES (STAINLESS STEEL) CONDENSER TUBES (NON-FERROUS) VACUUM PUMP EJECTOR AIR MEASURING DEVICE S S S Q S S S R R R S R Q Q R Q Q R Q PRODUCT : HEATER 1. 2. 5. 4. 3. 6.P. 9. 6. 2. 12. 5. 10. 17. 16. 3. 11. 15. 2. 1. 18. 19. 14. 7.1. 5.HEATERS PRODUCT : COOLER OIL COOLER CONTROL FLUID COOLER STATOR WATER COOLER HYDROGEN COOLER EXCITER AIR COOLER INSTRUMENTS / LOOSE ITEM R Q Q R R R R R Q Q Q Bharat Heavy Electricals Limited Rev 00. 4. 13. 8. 3. GLAND STEAM CONDENSER STAND PIPE INSTRUMENTS DRAIN COOLER L. 7-98 T1-08-0801G Page No.
NOMINAL DIA (d) OF ROPES mm 9 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 SINGLE CORD 522 1170 2150 3850 6200 9000 12200 16000 20200 24900 30100 35800 42100 48800 56000 63700 71900 81000 89900 99700 DOUBLE CORD WITH INCLUDED ANGLE OF 0o 1044 2340 4300 7700 12400 18000 24400 32000 40400 49800 60200 71600 84200 97600 112000 127400 143800 162000 179800 199400 45o 965 2070 4000 2100 11500 16600 22600 29500 37300 46000 55700 66200 77700 90200 103500 117700 132900 149700 166100 184300 90o 738 1580 3060 5400 8800 12700 17300 22600 28500 35200 42600 50700 59500 69000 79200 90000 101700 114500 127100 141100 120o 522 1170 2150 3850 6200 9000 12200 16000 20200 24900 30100 35800 42100 48800 56000 63700 71900 81000 89900 99700 Bharat Heavy Electricals Limited Rev 00.MAXIMUM PERMISSIBLE LOADING FOR WIRE ROPES IN KG. 26 . 7-98 T1-08-0801G Page No.
11. Matching of anchor plates of pedestal and LP base plates to ensure their perfect seating. Level / align LP outer casing lower half as per the transverse and longitudinal axis of the machine. Prepare shuttering and grouting of the pedestals and LP base plates including anchor plates of HP rear pedestal. Provisionally align and level all the pedestal and LP base plates as per the transverse and longitudinal axis including their elevation. 12. Prepare. Finally align and level HP front. 8. 6. Prepare and install LP base plates. Prepare and install steel bars for LP casing centralising keys in foundation slab as per the required center line . 3. install. Install permanent packers of LP outer casing including their radial and axial keys. LP rear pedestal along with their anchor bolts and anchor plates. Prepare . 4. Cleaning and checking of Turbine and Generator foundations as per the transverse and longitudinal axis including their elevation. align/ level both the LP girder along with their carrier plates. 2. 10.ERECTION SEQUENCE (For 500 MW Fixed pedestal type Turbine with spring loaded foundation) 1. 7-98 T1-08-0801G Page No. HP rear pedestal. LP front pedestal. 13. 7. HP front pedestal. 5. 27 . Weld locating ring of LP front pedestal and steel bars of LP front and LP rear centralising keys. Prepare and install LP inner outer casing along with gusset plates in position Bharat Heavy Electricals Limited Rev 00. HP rear. install and assemble LP front and rear end walls with the LP girders. 9. LP front and LP rear pedestals along with LP base plates as per the transverse and longitudinal axis including their elevation and catenary as per the design.
Transfer the load of HP rotor on bearings from the transport device and align it radially and axially. Record/ Ensure IP rotor float by shifting HP casing axially. Align LP rotor radially and axially in position and record free run out of rotor. 18. Provisionally align HP . 31. 17. 20. 21. (In case IP module is sent to site in disassembled condition. 23. 22. 25. Bharat Heavy Electricals Limited Rev 00. Align LP inner outer casing lower half and level it. 7-98 T1-08-0801G Page No. IP and LP rotor . Prepare and place HP module in position on temporary packers. Loading of IP rear end of the shaft on bearing and removal of transport device. Prepare and place IP module in position on temporary packers. Box up LP inner outer casing .14. Couple HP / IP rotor on temporary Bolts and align rotor / casing radially and axially. 28. 29. Prepare and install LP rotor along with their bellows in position. 27. Check free run out of HP rotor on journal and coupling face including its float. 28 . Prepare and install LP front and LP rear lower half shaft seals housing and align it provisionally. 16. refer Instruction T1-08-0606G. Box up LP inner inner casing and heat tighten the parting plane bolts. 26. 15. Conduct Horn drop test of HP casing without any radial and axial keys and pipe lines. 30. Assembly of breech nut of HP casing and Main Steam Stop & Control valve assembly. Conduct Horn drop test of IP casing without IP inlet upper half pipe lines. Install LP casing parting plane platform . 19. Record/ Ensure radial and axial clearances of the LP casing including rotor float including fitting of final axial keys of the LP inner casing . 24.
LP/Gen. LP/Generator and Generator / Exciter coupling after correcting the alignment including their couple run out and swing check of rotor on HP Front and exciter rotor. 41. Fixing of axial position of shaft and assembly of thrust bearing including its colour matching. Hall generator and thermocouples of bearing . 40. 34. 44.. T1-08-0909G. LP/IP. yoke keys etc. 43. Decoupling of HP / IP. Bharat Heavy Electricals Limited Rev 00. 33. Weld IP inlet upper half pipe and record Horn drop values without radial-axial keys. 45.32. assembly and calibration of thrust bearing axial shift. Preparations of the bearing for oil flushing. Turbovisory works in all the pedestal i. IP/LP . Alignment of HP/IP/LP rotors and their coupling on temporary bolts including its couple runout.e./Exciter coupling and rechecking of alignment/catenary after floating of TG deck spring. Swing check of HP rotor on its front end with temporary alternate bolt tightened on HP/IP coupling . Assembly of bearings and checking of all clearances including fittings of side pads of bearing. Preparation and floating of TG deck as per Instruction No. Gen. 42. 7-98 T1-08-0801G Page No. 37. 39. LP rotor expansions pick up. Erection of Reheat Stop & Control valve assembly. 46. 35. Oil flushing of the machine and normalizing the bearing after oil flushing. Roll check of HP/IP casing and fixing of radial and axial keys of the casing (Casing final packers need not to be put at this stage). 36. Final tightening of HP/IP. 38. MOP alignment and its doweling. Reaming/honing of HP/IP and LP/IP coupling including fitting of final coupling bolts. 29 .
52. 30 . HP exhaust . Checking /Correction of LP shaft seal clearance after floating of TG deck with CW pump in operation and water in the hot well of condenser upto operating level. 49. Preparation and boxing up of LP casing after competing the full Roll check of LP casing and fitting of final casing packers and radial keys. Assembly of final packers of the HP. IP casing after completing the roll check in up and down direction. Recording of final Horn drop of HP and IP casing after completing the welding of HP inlet. IP casing in up and down direction only with TG deck in floating condition and CW pump in operation including water in hot well upto normal level.47. Barring gear. Bharat Heavy Electricals Limited Rev 00. 48. Roll check of HP. 7-98 T1-08-0801G Page No. 50. IP inlet and Cross around piping. 51.
Check positioning of all the inserts and fixed points with respect to center line in transverse and longitudinal direction as per BHEL Hardwar drawings. Check verticality of all the pipe sleeves with the help of plumb. 31 . Ensure proper flatness of the bottom seating plate of all the inserts. Ensure proper stiffeners in all the vertical and horizontal embedment provided for various purposes like hangers and supports etc. Preserve machined surfaces of all the fixed points against any damages due to Improper handling. during pouring of concrete while vibrators are used. Ensure leveling on the fixed points of LP girder and LP rear pedestal. NOTE: In case of spring loaded TG deck refer Installation Instruction No. Check elevation of all points. CHECKS DURING CASTING/POURING OF CONCRETE Casting of foundation\TG deck should be carried out immediately after inspection of the foundation\TG deck i. within 3-4 days after final inspection to avoid any disturbance to the inserts and fixed point. 7-98 T1-08-0801G Page No. Ensure proper locking of all the insert and fixed points before grouting. T1-08-0909G prior to positioning of inserts etc.CHECKING OF FOUNDATION BEFORE CASTING Customer to provide.e. Ensure proper cleaning of the area before casting. center line and elevation point. Ensure no disturbance to the insert etc. Bharat Heavy Electricals Limited Rev 00. Remove all unwanted material.
Bharat Heavy Electricals Limited Rev 00. PREPARATION OF FOUNDATION FOR PLACEMENT OF PEDESTALS AND BASE PLATES: Foundation are to be cleaned and loose concrete are to be chipped off. CHECKING OF FOUNDATION AFTER CASTING Clean complete foundation and remove all shuttering etc. Cover all the opening before checking any dimensional measurement to avoid any accident. Measure pitching/elevation of all the inserts and fixed points. 32 . Maintain elevation of foundation to ensure correct thickness of non-shrink grout. Clean and deburr piping sleeves of the foundation on ID/OD of the pipe. Check level of LP rear pedestal fixed points and if required correction may be carried out. This may be welded on a I-beam near Generator. This point is to be preserved with proper protection. No repair should be done in this region without consulting the turbine erection engineer. A correct elevation reading is to be punched on this plate. For making reference point a one side ground plate of about 200 x300 x20 mm may be used. This reference point is to be used only during the turbine erection period. The ground position of the plate is to be kept on top side and all elevation are to be transferred from this point with the help of water level jar. Measure elevation of all foundation on different pedestal and LP base plate area. Alternately the pipe sleeve should be filled with sand. 7-98 T1-08-0801G Page No. Establish a suitable longitudinal axis considering the fixed point of the LP rear pedestal and various pipe sleeves / inserts. Close all the pipe sleeve from top to avoid entry of concrete inside. Ensure there is no loose concrete layer in the region where the pedestal and base plates are to be laid. Ensure all corners of the foundation remains perfect during chipping of extra concrete of foundation. Establish a transverse axis as 90 degree with the help of the odolite. A reference point for elevation in respect of machine center line (equivalent to LP rear pedestal) is to be maintained at a proper place.About 15-20 mm extra concrete may be left on top on all the pedestals and LP base plate area for chipping/cleaning purpose at a later date.
33 . Bharat Heavy Electricals Limited Rev 00. If required. If the error is nil then this may be punched as zero-zero. measure and punch half bore error of pedestal in left/right side of the pedestal. 7-98 T1-08-0801G Page No. Ensure that the pedestal parting plane is feeler tight after tightening all the parting plane bolts. colour matching may be carried out but scraping/cutting is to be done on upper half cover only. The half bore error of pedestals is punched by manufacturing unit however in case it is not there. Ensure there is no paint/oil on bottom face of the pedestal sole plate. Ensure correct fitting/clearance of locating rings of LP rear pedestal. Ensure there is no paint on inside surface or the pedestal and if required sand blasting may be carried out at site. Check proper colour contact of spherical/cylindrical supports of the bearing with the pedestal.PLACEMENT OF PEDESTALS Open and clean the pedestal.
Ensure that there is good contact available to the backing plate with the foundation.Check contact between spherical Torus piece of bearing and spherical/cylindrical seat. Match LP base plate with the individual carrier plate. Also refer T1-08-0808G. Do colour matching of all the eight nos. pedestal seal bores by fixing pianowire on individual pedestal. Assemble anchor bolts along with anchor plate of the pedestals. In case of any variation in contact no scraping/cutting to be carried out at site and this may be referred to manufacturing unit. Close opening of oil lines of pedestal to avoid any foreign material entering in these pipe lines during erection at site. carrier plate on both the faces. Weld MOP suction and discharge pipe lines in HP front pedestal as per the drawing before placement. Assemble protection sheet in the anchor bolt hole from bottom side of HP rear pedestal foundation to avoid entry of grout metal. PLACEMENT OF LP BASE PLATE. 34 . Adjust height of the Anchor Bolts as specified in the drawing. Assemble protection sheet in the foundation bolt holes. 7-98 T1-08-0801G Page No. Provisionally align and level all the four base plates. Bharat Heavy Electricals Limited Rev 00. Place all the four base plates in position along with their leveling screws and foundation bolts. Assemble protection sheet in the foundation bolt holes of pedestals. Ensure proper cleaning of base plate on bottom side. Put identification marks on each base plate to avoid any mistake in positioning of the same. If required colour matching/grinding may be carried out to achieve the contact. rear pedestal with 70-90 mm gap for filling of grouting concrete. Mark/punch center line on the base plate as per drawing. Check centering of individual bearing w. Ensure cleanliness of all pedestal oil lines. Ensure level of both anchor plate of H. OVER THE FOUNDATION : Clean all the four base plates.t.P.r.
LP base plates. Elevation of LP base plate is to be kept higher than the rear pair of LP base plate in line with catenary of rotor. 35 . HP rear and LP front pedestals. During welding of locating ring. Use measuring tape to maintain pitching of the bearing from one pedestal to another. After alignment of LP rear pedestal weld the locating rings as mentioned in the drawing.ALIGNMENT OF PEDESTALS AND LP BASE PLATES Provisionally align and level all the four pedestals including LP base plates with reference to the earlier marked longitudinal and transverse axis. Use piano wire arrangement with micrometer for centering of pedestal bore and use water level jar for setting of elevation. Elevation of the pedestals are to be set as per catenary of the machine considering the half bore error of the pedestal if any. Pedestals are to be set in level condition on both longitudinal and transverse direction. Align and level HP front. ensure that there is no movement in the pedestal in any of the direction. The elevation reference is to be taken from the already positioned plate for this purpose. 7-98 T1-08-0801G Page No. Bharat Heavy Electricals Limited Rev 00. Align and level LP rear pedestal and set the elevation as per machine center line. Align and level.
All anchor bolts are to be stretched minimum after 21 days of grouting. grout mixture should be poured in one lot only. before grouting. Water curing is to be carried out for about 10 days duration. HP.GROUTING OF PEDESTALS AND LP BASE PLATES Fill 3 to 8 mm washed Pea-gravel in all the anchor bolts sleeves. the mixture has to be poured from one end only and it has to flow to opposite end to avoid any blockage of air pocket. Use fresh stock of the grouting material only and check the strength of the material before use. Clean foundation with compressed air. Make shuttering of all the pedestal and LP base plates. Ensure matching and parallelity of front and rear key block of the HP casing. Seal anchor bolts holes after filling of gravel to avoid any entry of grout metal. PLACEMENT OF HP MODULE IN POSITION Ensure matching of all the four palms of the module where it is resting on the pedestals. 36 . Use thick polythene sheet inside the shuttering to give better finish and avoid moisture absorption by shuttering. Medical tape may be used for sealing of these anchor bolt holes. These gravel are necessary to give damping effect to the anchor bolts during operation of the machine. During grouting. For individual pedestal and base plate. coupling hole sizes and spigot dia of HP rotor. IP & LP module placement work can be taken up after 24 hours of grouting of the pedestal and base plates. Non shrinkage cement duly approved by BHEL is to be used for grouting of the pedestals and base plate. 7-98 T1-08-0801G Page No. Clean journals and coupling of the HP rotor. Bharat Heavy Electricals Limited Rev 00. Shuttering should be made with maximum care to avoid any leakage of grout concrete. All sides of the shuttering are to be sealed either with some sealing compound or with thick mixture of grout material to avoid leakage of grout material. Assemble all four jacking screw of HPC and ensure their free movement. Foundation are to be kept wet for about 6 hrs. Record journal dia.
Record spigot /recess. and coupling hole sizes. PLACEMENT OF IP MODULE IN POSITION Ensure matching of all the four palms of the module where it is resting on the pedestals. 37 . Ensure load on all four packers with the help of some additional shims if required. During placement of module use temporary packers similar to permanent and additionally support it by four jacking screws. 7-98 T1-08-0801G Page No. Clean IP rotor on both sides including coupling and journal. refer Instruction T1-08-0606G. Provisionally align the casing on front and rear pedestal bore. journal dia. ASSEMBLY OF LP MODULE This assembly can be divided in following sub assemblies: Bharat Heavy Electricals Limited Rev 00. Ensure matching and parallelity of front and rear key block of IP casing. Lift the module in level condition and place the module in position by moving about 7 to 8 mm towards generator end. section 20 before placing the IP module. Install temporary radial and axial keys of the casing. Assemble all four jacking screws of IP casing and ensure their free movement. Install temporary radial and axial keys of the casing with some shims. Ensure load on all four packers with the help of some additional shims if required. Prepare HP rotor for alignment (Ref.Lift module in level condition and place it in position by keeping it 3 to 5 mm toward front pedestal side. Use temporary packers for placement of module in position and additionally support the module with jacking screws. section 20). If these jacking screw holes are provided with the bolts from factory then same are to be removed before placement of module. Prepare IP rotor for alignment (Ref. NOTE: In case IP module is sent to site in disassembled condition.
Positioning of key block of LP casing axial keys. following works are also to be completed : . Plates. 7-98 T1-08-0801G Page No.Positioning and welding of LP casing centering pin of front and rear side. end plates are already provided in the foundation to take the radial load of the LP casing: Plumb the center line from LP front and LP rear pedestal bore on both side over the square plate of the foundation. POSITIONING AND WELDING OF LP CASING CENTERING PIN Two nos. Assembly / welding of LP outer casing. Before starting assembly of LP casing in position. Bharat Heavy Electricals Limited Rev 00. Assembly of LP inner inner and LP inner outer casing lower half.Positioning of all internal of condenser.Assembly of girder and end walls. Establish accurate position of the pin and put a punch mark at a required height and mark a circle and a controlling circle over all the four sq. Necessary pipe along with two sq. . centering pins are to be located below LP front and LP rear pedestal. . 38 .
Insert both the pins and carry out the welding as per laid down procedure. Bharat Heavy Electricals Limited Rev 00. Dye penetrate test on root run and after final welding is to be carried out. Ensure that the template is fitted with minimum clearance and hole center are perfect as per marking. The template dia must be very accurate and same may be made on machine.Dia of the circle must be equal to pin dia. A template equivalent to pin dia has to be made for this purpose with about 20 mm thick plate and a welded pipe for using as an handle. Preheating of 200 degree Celsius or more to be achieved before any welding. Insert key block on both the pins and weld their locking ring also. Make precise hole with gas cutting/grinding to match template on all four embedded plate. Before welding set correct axial position of the pins. 39 . Drill hole of about 10 mm dia on one of square plate of LP front and on one plate of LP rear for air venting to avoid cracks during welding. 7-98 T1-08-0801G Page No. Ensure proper clearances in key block before welding of its locking ring.
Provisionally align and level the girders. level LP outer casing and ensure contact of packers by colour matching/machining of spacer height. Install LP casing radial and axial keys. Lock with tack welding all the vertical joint bolts.ASSEMBLY OF GIRDER AND END WALL Colour match side matching flange of girder with the surface plate. Colour match side flanges of end wall. Do not make the groove by grinding. Match and ensure parallality of axial key ways of girder. Do colour matching with a surface plate on all four corner where argon welding have been carried out. Assemble front and rear end wall with the girders and ensure perfect parting plane level during tightening. Place left and right girder with carrier plate. Match and ensure parallality of key block of end wall. 40 . Set height of the girder equivalent to machine center line maintaining catenary of the machine with the help of water level jar arrangement. spacer and lubrite packer on LP base plate. Before welding make a V groove with the help of a chisel and allow the projection of material on surface. Assemble inner outer casing axial key blocks on left and right side of girder and dowel them. ASSEMBLY OF LP INNER INNER AND LP INNER OUTER CASING LOWER HALF The LP inner inner casing lower half is received from factory in assembled condition with LP inner outer casing lower half. Assemble locking plate of the front and rear end wall to facilitate its assembly with the girders. 7-98 T1-08-0801G Page No. Weld girder and end wall parting plane joint with argon welding. Put a seal weld run between girder and end wall joint all around except on top face. Bharat Heavy Electricals Limited Rev 00. Align. Colour match seating flange of girder where it rests over the LP base plate.
Colour match all eight carrier plates of inner casing on both side. Lower the casing in position over the carrier plates fitted with spacer and lubrite packer. Do colour matching on all four corners of the casing where it rest over the girder. 41 .Clean the casing and check all the threaded holes. Provisionally align the casing radially and axially. Screw jack is to be unscrewed after box-up. Bharat Heavy Electricals Limited Rev 00. Level and lift LP inner outer casing and assemble/weld both the gusset plates with the help of some temporary support. 7-98 T1-08-0801G Page No. Support the gusset plate with the help of screw jack (about 10-15 tons) on front and rear side by taking support from condenser stiffeners. Assemble all carrier plates on girder and do the colour matching with individual carrier plate. Prepare Gusset plate of front and rear side with temporary radial keys for fitting in LP inner casing.
7-98 T1-08-0801G Page No. Lift LP rotor with the supplied lifting beam in perfectly level condition and place it in position. Loading of each packer is to be ensured. Lower the casing by about 2 mm on all the eight packers with the help of shims for placement of LP rotor to avoid any fauling during placement of rotor. Bharat Heavy Electricals Limited Rev 00. Fit and weld all gusset plate stiffener pipes except pipe between LP inner outer casing and condenser. WELDING OF LP OUTER CASING The welding of LP outer cover is to be carried out before placement of LP Rotor in position to avoid damage to the rotor. Prepare shaft seal compensator along with gaskets (Gasket to be installed in fully ring shape only ) and position them on LP rotor with the help of supplied supports of compensator. spigot dia and coupling hole sizes. Ensure that all the eight packers have good contact. Place LP rear bearing in position.Adjust the height of the LP inner outer casing as per center line of the machine and then level it with the help of water level jar arrangement. During lowering of rotor ensure radial clearance with the help of long feeler gauges in the LP casing. Do not make any weld connection between condenser and any of these stiffeners till neck welding of the condenser is over. PLACEMENT OF LP ROTOR Measure journal dia. Ensure centering of temporary bearing support in the LP front pedestal for placement of LP rotor. 42 .
Weld/lock LP upper half flange with respect to lower half casing with the help of metal cleats to minimise the distortion during welding of LP cover. pos. Side flange of LP front and rear cover are to be ensured in right angle to achieve good contact with their matching flanges. WELDING PROCEDURE Tack weld the crowned seam joint.Colour match and remove all high spots of the matching flange of the LP outer casing. Ensure good contact between parted diffuser of LP front and LP rear cover. If necessary colour matching may be carried out to achieve a feeler tight joint. 1. Opposite tack welded radial joint 2. permanently weld approx. Achieve the fitting clearances for welding as per laid down procedure. 100 mm at the generator end of the joint. After fixing of LP front and rear cover measure the dimension for positioning of both the center flanges. The center flanges are supplied in extra length on both sides from the factory and final length are to be maintained at site only. Ensure matching of parted diffuser face on both side of LP casing. The dimension are to be recorded in such a way that there is no clearance after fitting of center flanges in position on both side with the LP front and rear cover. Fit both the center pieces of the cover in position. permanently welding approx. Do not over tighten parting plane bolts. staggering the two weld ends to ensure a perfect transition when the crowned seam joint is finish welded. Colour match and remove all the high spots of the parted diffuser/vertical face to ensure good contact with the compensator at a later stage. Ensure drilling and reaming of all dowel pin holes to equal depth. The joint must be feeler tight just after normal tightening of bolts. Place LP front LP rear cover along with parted diffuser and ensure feeler tight joint after tightening the parting plane bolts. The cleats may be welded at an interval of about one meter distance. 7-98 T1-08-0801G Page No. 43 . Drill/ream all the parting plane holes as per drawings and install all dowel pins. Bharat Heavy Electricals Limited Rev 00. Drill/ream dowel pin holes in center flanges and install all dowel pins in position. Carry out the welding as per the following welding procedure. Colour match and remove all burrs and high spots from parting plane of LP outer casing. 100 mm of the crowned seam joint.
44 . Weld radial seam at TE according to welding sequence plan. release top half casing and lift to insert and tack filler piece between joint strips. Align shell courses on joint strips and tack weld. 7-98 T1-08-0801G Page No.Tack weld the crowned seam joint at regular intervals with a tack of 5T and pitch of 25T. Unbolt top half casing and lift in order to weld and finish . Now this alignment activity of all the three rotor can be divided as below : Bharat Heavy Electricals Limited Rev 00. rest on but are not tacked to the retaining strip in the region of joint 1. Insert pins in top half casing. shell plates 1 & 2. adjust and tack weld radial seam at GE. When welding radial joint 2. tacked together. Weld on joint strips from center & ends of shell plate. The tacking & welding sequence applies for all shells courses. Weld radial seam at GE according to welding sequence plan. so that any shrinkage occurring during welding of seam 2 is not obstructed. ALIGNMENT AND COUPLING OF LP-IP & HP ROTOR LP rotor is to be aligned on pedestal seal bore and LP inner outer casing is to be centralised in such a way that enough clearances are available to LP rotor.machine filler pieces in the region of the joint surface. Check welds according to specifications. Weld crowned seam joint. during alignment. Align.
honing of the coupling holes. Fix temporary radial and axial key of the casing on both front and rear side of the casing.20 mm on front side by putting additional shims in front packers. If required move complete HP module along with the rotor. Lift module by 0. PREPARATION OF HP ROTOR FOR ALIGNMENT Align HP rotor with reference to front and rear pedestal seal bore reading. Reaming. Insert HP front bearing in position. If required further lower the front side of the module to achieve the loading on bearing by about 0.Preparation of HP rotor for alignment. Reduce 0.10 mm load on the rotor. Remove HP front upper half transportation device. Bharat Heavy Electricals Limited Rev 00.10 mm.20 mm shims gradually and ensure about 0. Preparation of IP rotor for alignment. 7-98 T1-08-0801G Page No. Preparation of LP rotor for alignment. 45 . Balancing of coupling bolts weight. Alignment of LP-IP & HP rotors.
Insert and load the bearing in HP rear end in similar way as carried out in case of HP front end and record axial position of rotor as per shop protocol. Lock axially HP rotor with some fixture along with the arrangement of jacking screw for movement of rotor. This may be ensured by checking with feeler gauge also. Check axial position of HP rotor in front side on left. This fixture may be mounted on rear pedestal. 7-98 T1-08-0801G Page No. 46 .Remove HP front lower half transport device gradually and ensure no movement between HP casing and rotor. During loading of bearing always ensure that the rotor is not fouling inside the casing with the shaft seals. (Ref. If necessary. If necessary adjust shims of HP casing front packers. move the casing readily to achieve the centering. Check axial run out on thrust collar and both the coupling faces of HP rotor. Check HP rotor radial run out on journal and coupling. It is recommended to place upper half of bearing in position to avoid dust and any other damage to the shaft journal. Before locking of rotor ensure axial position of the shaft. Use thick oil during rotation of shaft on the bearing. PREPARATION OF IP ROTOR FOR ALIGNMENT The IP module is also to be prepared in line with the HP module. The additional point which are to be taken care are explained below : Bharat Heavy Electricals Limited Rev 00. However as IP rotor is provided with one side bearing and opposite side is coupled with the HP rotor without a bearing. Protect bearing from any of the dust particles. A fixture can be fabricated at site for mounting the dial gauge on both the end of the rotor to check the centering of the shaft. extra care is necessary during alignment of rotor in IP casing. Realign the rotor shaft with respect to pedestal seal bore and if necessary adjust the shims below spherical support of the bearing. Check axial float of the rotor. Compare values with shop protocol values. Deviations to be reported to Manufacturing Unit. Care should be taken during alignment that radial and axial clearances between rotor and casings does not get bridged. right and top position from the rotor reference point to the HPC as given in the shop protocol. T108-0802G). Center HP shaft with reference to HP casing front and rear spigot.
7-98 T1-08-0801G Page No. During coupling of the rotors. During checking of float ensure HP casing is not fouling with HP rotor. Bharat Heavy Electricals Limited Rev 00. IP casing and adjust as per shop protocol. T1-08-0802G).r. Align LP inner outer casing radially with the help of long feeler gauges and install temporary radial keys in the gusset plate.Place IP rotor rear end on bearing similar to the HP rotor and remove transportation device. Check centering of IP rotor front and rear end w. If required HP casing may be moved axially for this purpose.r. Compare values with the shop protocol values.t. 47 . PREPARATION OF LP ROTOR FOR ALIGNMENT Provisionally align LP rotor in pedestal seal bore placing the front end of shaft on auxiliary bearing and rear end on bearing.t. the transportation device of IP front end is also to be taken out. Check facial runout on IP rear coupling face and radial runout on journals and couplings. Provisionally align HP/IP rotors and couple on temporary bolts by moving both the modules. IP casing (similar to the HP rotor centering check). Check float of the IP rotor. (Ref. Check axial position of rotor w.
Parting plane bolts of LP inner-inner casing are to be heat tightened. If necessary individual rotor module can be taken out for correction of coupling face runout. The adjustment of shims in the bearing should be within the permissible limits only. Record radial run out of LP rotor coupling and journal and axial run out of the coupling faces of the both end. Ensure that the higher point of the rotor coupling face and lower point of another rotor coupling face are matched together. Hand tighten the coupling bolts by keeping a gap of > 1. 48 . Any variation on radial runout of rotor is to be referred to the factory. Bharat Heavy Electricals Limited Rev 00. IP AND LP ROTORS Ensure radial and axial runout of all the three rotors are individually in order. During alignment achieve left and right movement of the rotor with the help of shims in spherical / torus piece of the bearing. Rotate the rotor system and record the coupling gap at 90 Deg. Check/record spigot clearance of HP-IP and LP-IP rotors by actually moving them in spigot. The up and down movement of the rotor is to be achieved with the help of shims in the cylindrical/spherical support of the bearing . This is to be compared with shop protocol also. Record float of the LP rotor by moving the LP inner outer casing lower half. Match coupling faces of two rotor as per the axial face reading of the rotor. ALIGNMENT OF HP. Remove shims from the front end of auxiliary bearing and keep rotor on lifting tackle. supplied bolts along with one/two pins in HP-IP and LP-IP coupling. bolts and pins remain free while recording the gap of the coupling for the alignment purposes. Ensure that the coupling. Install four nos. Variation if any in radial or axial clearances are to be corrected/approved at this stage. After ensuring the radial and axial run out of the LP rotor the LP inner outer casing can be boxed up.Record all the radial and axial clearances of the LP casing without coupling the LP-IP rotor. Preliminary align radially and axially all the three rotors and shift them in spigot along with the casing to avoid fouling of rotor inside the casing.00 mm in coupling faces for alignment. 7-98 T1-08-0801G Page No. interval on left. right and top position. Ensure during alignment that the catenary of the shaft is maintained.
In case. rotor if it Ensue that the coupling holes are properly aligned to avoid unnecessary enlargement of holes. BALANCING OF COUPLING BOLTS After fitting the coupling bolts in all the holes these are to be balanced within 5 gms accuracy and an accurate balance which can take a load of about 20 kg. do not enlarge all the holes. Do not decouple the coupling in any case without ensuring the fitting of all the coupling bolts.005 mm. The above value must be within the prescribed limit only otherwise a correction must be carried out at site in consultation with designer.02/0. As a special case in such cases these few holes may be left as oversize. Bharat Heavy Electricals Limited Rev 00.03 mm clearance with sliding fit and bolts are to be ground within an accuracy of 0. Release the couplings for reaming / honing of couplings. Do not rotate the is tight during its rotation.02/0.Check swing check value of the HP rotor with alternate bolts in position. Coupling bolts are not to be hammered in the holes and these are to be fitted with thumb pressure only. 49 . Ensure free movement of rotor on their bearing. refer alignment procedure 0909G T1-08- REAMING / HONING OF COUPLING Ensure that there is no disturbance on coupling during reaming/honing operation.005 mm. few holes have gone considerably over size during reaming/honing at site/works. 7-98 T1-08-0801G Page No. First ream/hone two opposite holes of the coupling and install two pins/bolts with sliding fit and then take up all other holes. Ensure HP-IP-LP rotor radial run out after tightening with alternate clearance bolts. The length of the pin should be equal to the bolt length. In case of spring loaded TG decks.03 mm clearance. This can be ensured by checking hole with a straight ground finish pin having 0. Enlarge coupling holes to the minimum possible diameter and try to make all the holes to same dia. Ensure that the finished holes are straight and there is no banana shape. Ensure that the holes during reaming/honing are perfectly finished as ground bore and size obtained should be within 0. Ensure all the coupling bolts are fitted within 0.
During colour matching a good contact on all the pads of front and rear side are to be ensured with respect to rotor collar by moving the rotor in +/. COLOUR MATCHING OF THRUST BEARING After completion of reaming/honing and preliminary tightening of the coupling bolts. 50 . The amount of excess weight must be equivalent to the excess enlargement of hole at site. When the holes of the coupling are of different sizes then it must be seen that whether excess enlargement have been done at site or works. the colour matching of the thrust bearing pad have to be carried out with respect to the thrust collar of the HP Rotor. If all the coupling bolt hole sizes are same before/after reaming and honing then all the bolts can be kept of equal weight. Following points are to be taken care during colour matching. During balancing of coupling bolts following points are to be taken care. If necessary adjust the weight of the bolts by machining the metal from the bolt head. 7-98 T1-08-0801G Page No. Final balancing of the coupling bolts are to be done along with the coupling nut of individual bolt. In such cases if excess cutting have been done at site in a particular hole then coupling bolt with excess weight are to be used. Bharat Heavy Electricals Limited Rev 00. If a particular hole of excess dia.may be used. is noticed from factory then it is assured that the particular rotor is balanced with excess dia hole and there is no need of providing excess weight bolt at site.direction during its hand rotation.
51 . After colour matching of the thrust pad the axial zero position of the rotor is achieved and this can be taken for all other future reference for setting of axial position of HP. Axial keys to be fitted while finalising the alignment of thrust bearing with rotor collar without pads. During moving of the spherical support in front or rear direction ensure that there is no left . IP & LP casing. Colour is to be applied on the thrust collar of the rotor. IP and LP lower casing are to be set axially after fixing the axial position of the rotor and their final axial keys can be installed at this stage. 7-98 T1-08-0801G Page No. If necessary move the spherical support of the bearing pedestal to ensure the equal thickness of the pads before fittment of axial keys of the bearing. Few drops of oil is to be put on journal portion of the thrust bearing during rotation of rotor to ensure that the oil is not entering in pad portion of the bearing. Bharat Heavy Electricals Limited Rev 00.right movement to the support otherwise that may cause misalignment of the bearing. HP.Thrust bearing must be axially locked with the help of axial keys during the colour matching of the pads.
The roll check have to be carried out in HP. During fitting of casing axial keys and palm packers ensure proper contact on lubrite coating of the keys/packers to avoid any damage of these coating during operation of the machine.r. After completion of fitting of final keys and packers only the casing are to be cleared for further works of welding of various pipe lines. balancing leak of lines. IP & LP CASING After completion of colour matching of the thrust bearing pads the casing alignment work can be taken up. Offset center line of the HP.r. 52 . TG deck springs are to be kept in floating condition while recording the roll check of LP casing. However the roll check of HP/IP casing may be carried out before floating of TG deck for fitting of their radial keys but up and down roll check of HP/IP casings are to be done with TG deck in floating condition as per the procedure TS/ST/ 01/0008/00/96. 7-98 T1-08-0801G Page No. IP & LP casing w. steam inlet and exhaust pipes are to be welded with HP casing after fitting of final axial keys and packers of the casing. casing front and rear spigots. IP and LP casing. The following points are to be taken care while aligning HP.t. Center HP rotor w.ALIGNMENT OF HP. The welding of steam inlet pipes between LP inner casing and LP girders are to be taken up after completion of roll check of the casing. IP and LP casing are to be fitted with final packers and axial key immediately after the roll check.t. Ensure that there is no obstruction in the movement of LP inner casing due to welding of any of extraction piping. IP and LP casing to ensure the correct radial clearances of the casing. The one of the joint of extraction piping may be left free till completion of roll check of the casing. Bharat Heavy Electricals Limited Rev 00. The gland steam. HP. respective rotor center line as per recommended logsheet. Compare the readings with shop protocol and record the readings.
GEN/EXCITER couplings are to be reopened and realigned after completing the reaming /honing . Ensure adequate clearance between LP inner inner casing and LP inner outer casing to avoid any obstruction during expansion of the LP inner casing inside the LP inner outer casing during operation of machines. Ensure proper cleanliness of the LP inner inner and LP inner outer casing. After checking of alignment /catenary the final couplings are to be tightened including their coupled run out and swing check of rotors on HP front and Exciter end of the shaft. Before roll check of LP casing all the stiffener pipe welding work must be completed.Check/record LP diffusers centering readings after roll check of the casing. BOXING UP OF LP INNER INNER AND LP INNER OUTER CASING The boxing up of LP inner inner and LP inner outer casing can be taken up before starting the alignment of HP-IP & LP rotor for coupling work. Check/record all the radial and axial clearances of the casing. The rotors alignment are to be checked with TG deck in floating condition as per the laid down procedure. Refer T1-08-0909G. fitting of cap nuts and accessibility of spanner . Ensure feeler tightness of the parting plane joint of both the casing. 53 . 7-98 T1-08-0801G Page No. FINAL TIGHTENING OF COUPLINGS In case of spring loaded foundation after completing all other works the HP / IP . The following points are to be taken care before/during boxing up of these two casings. Bharat Heavy Electricals Limited Rev 00. IP/LP . BOXING UP OF LP OUTER CASING During the boxing up of the LP outer casing following points are to be taken care. Ensure matching of all the parting plane holes. LP/GEN .
Ensure proper assembly of parting plane rubber cord. 54 . Ensure feeler tightness of bursting diaphragm flange joint before boxing up of the casing.Roll check of LP inner casing including the fitting of key. Ensure matching of all parting plane holes and feeler tightness of the joint before boxing up of the casing. packers etc. must be finished. Bharat Heavy Electricals Limited Rev 00. All the works must be finished inside the LP casing before boxing up of LP casing including LP extraction pipe line works. 7-98 T1-08-0801G Page No. IP exhaust and other piping of HP/IP casing the final horn drop readings are recorded as per the laid down procedure mentioned in the manual for horn drop check. However the IP casing horn drop is also to be recorded with IP inlet upper half pipe welded with casing alone. HP exhaust. FINAL HORN DROP CHECK After completing the welding of HP inlet. IP inlet.
refereed from the manufacturers brochures. should be PROCEDURE The foundation should be thoroughly cleaned. a large size filling heaped should be used. As the grouting compound remains workable for a limited time. mixing time. Caution: Preparations for grouting. Bharat Heavy Electricals Limited Rev 00. 7-98 T1-08-0801G Page No. it must be poured from one side only. to prevent air bubbles. NOTE:. from surfaces by wire brushes to ensure proper adhesion of the grouting compound. SETTING UP OF SHUTTERING Set up shuttering from suitable material in box like manner around the foundation plates and secure it firmly. grease etc. 55 . bearing pedestals.Remove all rust preventive paints. For this. foundation frame with shrink-free grouting compound is intended to ensure uniform transmission of the force and vibration of the TG unit to the foundation. and grouting must be carried out with great care as it is no longer possible to check and rectify the parts once they have been grouted. CONBEXTRA GP-II or equivalent should be used as grouting compound. quantity of water to be mixed.Shuttering must be sealed well to prevent the liquid grouting compound from running out. Further details on the grouting depths. All foundation bolt holes should be filled with pea-gravels and covered at the top to avoid entry and sticking of grouting materials with the bolts. NOTE:.Grouting of turbine base plates. This can be done by using paste of grout materials and allowing it sets.
56 . Two or more mixers are required for grouting of bearing pedestal foundation frame. -Provide adequate workmen for grouting. Then add gradually the grout. -Ensure uninterrupted power supply to the mixers and EOT Crane for handling the ready mix. -Store the grouting compound next to mixer. This is to be done as per recommended FQP -Take 80 % of the required water quantity first in the mixture. Finally add the balance quantity of water and mix for atleast another five minutes Bharat Heavy Electricals Limited Rev 00.PREPARATION OF GROUT MIX Following measure must be taken before commencing mixing and grouting due to limited time that the grouting compound remains workable. The capacity of the mixers. 7-98 T1-08-0801G Page No. Keep the foundation moist for at least 6 hours before the grouting.Ensure that the compound is well within its expiry date. -Ensure six empty cubes for filling the grout for strength testing. . should be adequate to cope with the quantity of mixed cement required at a time. -Set up mixers in the immediate vicinity of the foundation plates. ensuring that no lumps are found. It is desirable to add five or six large sizes stones to break any lumps. -Provide the water hose and measuring pans near the mixers.
8. (Flow may be accelerated by moving the grout in the filling nozzles underneath the plates with chains or material strips. 3. After the grouting compound has set (approximately. Do not use concrete vibrator. Pour in one continuous operation. without interruption. The hopper must be big enough to make the full quantity of grout. 7-98 T1-08-0801G Page No. Than pour the grout with a hose through the filling hopper until the desired height is achieved on the opposite side. 2. and the level of grout has fallen below the base plate level. remove all shuttering and smooth off the excess grout. Do not install any woven steel fabric reinforcing mats beneath the foundation plates.) This should be done only if it is permitted by the grout supplier. CAUTIONS 1. It is desirable that in hot weather the grouting is done in the evening so that ambient temperature is low during the initial setting time. Due to short workability times. 6. Water should be clean and free from dissolved chlorides. NOTE:. it is desirable to wash out the complete grout. In case during the grouting operations heavy leakage is observed from the shuttering that cannot be plugged during the grouting operation.After at-least 72 hours setting time. The grouting compound is subjected to Bharat Heavy Electricals Limited Rev 00. 4. Pour grout from one side only so that no air bubbles remains entrapped in the grouting compound. never mix more grouting compound at one time than is required for one plate or volume to be grouted. as these weaken the grout. 7. 57 . 5. The operation should be repeated after the shuttering has been rectified. 24 hours after grouting).This mixture is then taken into through heaped mesh. work may be commenced on pretensioning of the foundation both.
58 .compressive forces only. These can be avoided by covering the exposed areas of grout by polythene sheets to avoid excess loss of moisture during initial setting. Bharat Heavy Electricals Limited Rev 00. Resultant hair cracks are insignificant with regard to TG stability. 7-98 T1-08-0801G Page No.
the same will be dispatched to site in dismantled condition in various packages after completing the shop assembly at Hardwar. The coupling will be opened and again re-aligned after floating of the TG deck which is generally done after erecting all the components of Turbine -Generator including their piping etc. Install temporary radial keys of the IP outer casing with the pedestal. The above machines are equipped with the spring loaded foundation deck. Afterward complete casing will be dismantled and dispatched to site. ASSEMBLY PROCEDURE AT SITE : Place IP outer casing lower half in position after its cleaning over the pedestals by supporting it on the Jacking screws at four corners of casing. 59 . During placement Bharat Heavy Electricals Limited Rev 00.63) and its limitation in transportation from Hardwar to site. Clean and install IP inner casing lower half along with its radial keys (Drg. Additionally support the casing on temporary packers with the pedestals also. No. 7-98 T1-08-0801G Page No. As a general requirement initially all the turbine and generator rotors will be aligned/coupled without floating the TG deck. 25) of front and rear end. 0-106-0127500 item No. Align IP outer casing radially with the help of piano wire keeping the HP rear and IP front pedestals seal as reference.ASSEMBLY PROCEDURE OF IP MODULE Due to oversize dimension of the IP module (M30 . First the complete assembly of IP module will be done at works except the heat tightening of parting plane bolts of IP inner and IP outer casing.
60 . Assemble IP inner casing upper half end tighten the alternate parting plane bolts to ensure feeler tight joint. parting plane studs (drg N. During this process the heat tightening the bolts are not necessary as this is required for ensuring the feeler tight parting plane joints of the IP inner casing. Jacking screws. Loosen IP inner casing parting plane bolts and remove IP inner casing upper half. 0-106-01-27500 # 3.of inner casing support it on its four nos. Decouple and lift IP rotor for assembly of rear end shaft seals of IP casing. (Drg no. Align radially IP outer casing with reference to the IP rotor on front and rear glands. Place IP rotor in position after its cleaning. During placement of IP rotor ensure that the rotor is free on its seal fins of IP inner casing and necessary the IP outer casing may be lowered on its rear end.9. Before placement of inner casing install its thermocouple. Check IP rotor axial float in IP inner casing and compare with shop protocol. 0-106-0127500# 18).4. Bharat Heavy Electricals Limited Rev 00. 0-106-01-27500 # 21) and rear end of the rotor on its bearing. Set axial position of the IP rotor as per the zero position of the thrust bearing and set axial position of the IP outer casing as per Hardwar protocol on front and rear end of the IP outer casing. After placement of inner casing install its axial keys (drg N. Loosen IP inner casing bolts and remove IP inner casing upper half. Provisionally align and couple HP/IP/LP/ Generator rotors and complete reaming /honing of the coupling including swing check etc. 0-10601-27500 # 20). The front end of the seals may also be assembled now of afterward with the IP rotor in position. Recheck/correct axial position of the IP casing. Before rotation of IP rotor remove segment (drg N. 0-106-01-27500 # 33 & 34 ). Seal ring of inlet insert & extraction line (drg N.14 ). The IP inner casing packers are also to be installed during tightening of the P/P bolts and load of the inner casing is to be transferred on these casing packers (drg N0-106-01-27500 # 17) fter taking the load on the packers release the jacking screws of the IP casing. Ensure / compare roll check values with shop records.10. Do roll check of IP inner casing by moving the IP outer casing in left/right direction and IP inner casing itself in up/down direction with the help of inner casing jacking screws by removing the inner casing packers. The front end of the rotor is to be placed over segment (drg N.13. 7-98 T1-08-0801G Page No. Place IP inner casing upper half in position and tighten alternate parting plane bolts. Before loosening the IP inner casing parting plane bolts support inner casing again on its four jacking screws and ensure that the parting plane level of lower half inner casing is not disturbed and remain same as it was kept after tightening of parting plane bolts with load on its four packers. 0-106-01-27500 # 21).
7-98 T1-08-0801G Page No. depending on the site conditions the same may be suitably reviewed. Before placement of IP outer casing upper half assemble casing shaft seals of front & rear end also.7. Do roll check & float of completely assemble IP turbine and compare it with factory protocol. if necessary.12).63 at site. NOTE : These are general instructions for the assembly of IP module M 30 . Install seal rings of inlet insert and extraction pipe on IP inner casing upper half (drg N. However. Assemble and heat tighten IP inner casing upper half as per required elongation of parting plane bolts.2. Assemble IP outer casing upper half and tighten the parting plane bolts to ensure feeler tight joints. and carry out final roll check and float of completely assembled turbine. The heat tightening of the bolts are not to be done now. The taper pins of IP inner casing parting planes are to be removed before placement of IP outer casing upper half after the heat tightening of IP inner casing bolts. The IP rotor may not be coupled at its rear end with the LP rotor at this stage. 61 . Heat tighten IP outer casing parting plane bolts to required values.8. Bharat Heavy Electricals Limited Rev 00. 0-106-01-27500 # 1.Place IP rotor in position and provisionally couple it with HP rotor on temporary bolts.11.
BREECH NUT THREADS. PACKERS. Bharat Heavy Electricals Limited Rev 00. JOINT PLANE OF BEARING PEDESTALS. JOINT PLANE OF LP OUTER CASING (WITHOUT RUBBER SEALING CHORD). MOP CASING. 7-98 T1-08-0801G Page No. HP FRONT & REAR BEARING PEDESTAL PACKERS (OTHER THAN SELF LUBRICATED LUBRITE PACKERS). PACKERS. THREADED FASTNERS INCLUDING. KEYS. GLAND BOXES & STRAINER HOUSINGS.SEAL RINGS IN HIGH TEMPERATURE ZONE. 62 .SEALING & ANTISIEZING COMPOUNDS SNO 01 LOCATION JOINT PLANE OF HPT IPT & VALVE CASINGS. KEYS. THREADED FASTNERS. ZONE. VALVE SERVOMOTOR. DOWEL PINS IN LOW TEMP. DOWEL PINS U & I . COUPLING BOLTS SEAL SEGMENTS. HP/IP CASING PALM PACKERS. FEATURES METAL TO METAL JOINT IN HIGH TEMPERATURE ZONE RECOMMENDED COMPOUND − BIRKOSIT − STAG B − MAGNESITE COMPOUND OF BHEL BHOPAL − HOLDITE − LOCTITE 574 − HYLOMER − GOLDEN HERMETITE − VICTOR SHELLAC − MOLYKOTE P37 − OKS 255 02 03 METAL TO METAL JOINT IN LOW TEMPERATURE ZONE METAL TO METAL JOINT IN OIL ENVIRONMENT 04 HIGH TEMPERATURE ( < 350°c) ANTISIEZING 05 LOW TEMPERATURE ( < 350°c) ANTISIEZING − MOLYKOTE D 21 − OKS 511 − MGS 400 NOTE: NO COMPOUND IS TO BE APPLIED ON SELF LUBRICATED LUBRITE PACKERS. BREECH NUT MATING FACE.
ASSEMBLY OF BEARING AT SITE GENERAL DESCRIPTION The KWU design machine are supplied with four bearings out of which three are the journal bearing and one is combined thrust and journal bearing on H. This can be done even before the placement of pedestal in position for grouting. All the turbine bearing are self aligning type and they adjust themselves as per the catenary of the machine. sphere to sphere in HP front and HP rear bearing and torus to cylindrical in other bearings. Bharat Heavy Electricals Limited Rev 00. 63 3. In case of Thrust and Journal bearing the seat of the bearing neither doweled from the works nor it is recommended to be doweled at site. Ensure torus/spherical contact with their seats at site. If these lines are not straight T1-08-0801G Page No. Measure bore dia of the bearing and journal dia at site and ensure the oil clearances. After opening the pedestal remove and clean the bearing including its spherical/ cylindrical seat. 5. The function of a journal bearing is to support the turbine shaft . ASSEMBLY PROCEDURE 1. The contact arrangements between bearing and bearing supports are of two types i. Ensure 0.P. While checking the contact the seat may be bolted with their pedestal. If any discrepancy is observed . After alignment of the bearing in their pedestal the seat of the bearing are doweled before dispatch to site. In case of any variation the matter may be referred to designers. 7-98 . 4. Remove oil guard ring and its duct and keep them in proper place for their storage at site. rear end of the shaft.03 feeler tightness on bearing parting plane. During storage at site avoid direct loading of bearing on its torus.e. 6. but the thrust bearing support the shaft as well as work as a fix point for the turbine shaft. designer may be referred. In case variation contact from their specified diagrams are noticed then following may be carried out at site:a) In case of torus to cylindrical seats the line contact are recommended by designers. 2. The bearings are supplied to site after ensuring their contact at works. During erection all the bearing are supplied to site in aligned and assemble condition in their individual pedestal from the works. The bearings need preparation before placement of module in position at site. Handle bearing carefully to avoid any damage to the babbit and its torus/spherical piece. A thick rubber seat may be used during handling of bearing at site on its torus.
and are in angle then the bearing may be rejected straight way and sent to works for rectification. These line contact may be in a width of about 20 mm throughout on its seat leaving with area on both sides. The contact may be wide in Center and then gradually reducing on sides. In case there is no contact is achieved in the center and only sides are having contact then a feeler gap may be recorded in bottom. In case if the bottom is tight to a feeler of 0.03 mm the bearing may be accepted at site without doing any rectification. b) In a reverse case the contact are achieved in center only though the 0.03 feeler is not going in the side. The bearing may be still accepted at site. In case if the feeler is going in the bottom or in sides by 0.03 mm. the bearing are not accepted at site and can be sent back for the rectification to the works. Similarly if the contact are intermittent on its seat but in a straight line and no feeler is going the bearing may be accepted. In case of very wide contact also the bearing may be sent back for the rectification. While checking these contact very light color may be put on torus of the bearing. Before sending back the bearing to the works the matter may be referred to designers and their concurrence is to be obtained. No scrapping/lapping is recommended in these bearing for improvement of the contact.
In case of spherical to spherical bearing the contacts are called in the center like a moon shape. In these bearings even full contact may be accepted. But in case if there are contact on sides and a feeler gap is noticed on center then the bearing may not be accepted. In such cases if the gap is upto 0.03 mm then the matching/lapping may be carried out at site. But in case of higher gap the matter may be referred to designers. In case of reverse case if the feeler gap of 0.03 is noticed on both sides of the bearing the bearing may not accepted at site and matter may be referred to designers.
Bharat Heavy Electricals Limited Rev 00, 7-98
T1-08-0801G Page No. 64
Before checking the contact between torus and its seat ensure that the seat is feeler tight to 0.03 mm without tightening of any bolts with the pedestal. If necessary this may be corrected with consultation of designers. Similarly ensure contact between torus\ spherical piece with bearing and in case of variation the matter be referred to designers and no correction is to be carried out at site without the approval of manufacturing unit. Before checking the contact between torus/spherical piece with bearing and in case of variation the matter may be referred to designers and no correction is to be carried out at site without their recommendations. The sizes of all the shims may be punched in bearing body and spherical/torus piece of the bearing. The number of shims are to be limited to 3-4 numbers only even after complete alignment of machine. A protocol for number of shims may be prepared. Torus/spherical should not have any radial movement over its bearing. This can be seen after opening the torus from the bearing. Check jacking oil lines of the bearing and clean them thoroughly. Ensure jacking oil lines fittings also for their male female threads etc otherwise this may create the oil leakage through these lines during operation of the machine. The jacking oil pocket in the bearing may be checked if necessary they may be corrected at site as per the drawings. When ever JOP is not available, use always thick oil during rotation of shaft over bearing.The type of oil may be used as servo cylinder 1000 grade of IOC. After installation of bearing in position the oil clearances may be checked after few rotation of the shaft. But the final oil clearances are to be checked after final coupling of the shaft. In case of variation in side oil clearances no cutting of babbitt metal is permitted at site. Any variation in clearances may be counter checked by measuring journal / bearing bore dia. Bearing bore dia is to be measured by assembling and tightening of top & bottom halves of bearing. In case of skew side oil clearances, the investigation may be carried out, if necessary consult manufacturing unit. Ensure good contact between journal and babbitt metal of the bearing in the center. Any minor high spot may be removed from the babbitt metal while checking with blue color. Ensure full contact of shaft over the jacking oil pocket also. T1-08-0801G Page No. 65
Bharat Heavy Electricals Limited Rev 00, 7-98
Always cover rotor journal with the upper half bearing to avoid entry of any sand particles etc. in the bearing . During pouring of oil the upper bearing may be removed and replaced back after the pouring of oil. After completing the reaming/honing and final tightening of coupling bolts the work of bearing side pad, yoke keys and oil guard fitting may be taken up. Before starting the side pad and top keys ensure that the bearing is perfectly level on parting plane. Ensure that the gap for the side pads are parallel otherwise these are to be made by cutting/scrapping. After fitting of the bearing cap if the gap for the radial top keys are in taper a proper correction is to be made here. The bearing cap may also be repositioned to achieve the parallelity of the key way. The cap may be re-doweled after repositioning it but no taper are to be left on these area. If repositioning of cap is not helping then the cutting may be carried out in bearing cap. The gap for the top packer of bearing may also be checked. In case of any taper the same is to be corrected by cutting on bearing cap. Sometime the size of this packer comes to very low i.e. even below 5.00 mm. This may be corrected by matching the cap and size for this packer may be kept around 6.00 mm. On all these bearing cap key a proper fitting and clearances are to be maintained during assembly. These key of proper material are to be only used and no welding deposits are permitted here. The new key may be made at site by EN-24 material if correct key are not available at site. Use of local made shims in bearing may be avoided and shims supplied from the works with proper cutting of holes are to be used. Ensure drawing requirement of maximum adjustment at site by + 0.3mm in shim size from manufactured condition. A proper care should be given during fitting of bearing oil guard ring otherwise it causes the oil leakage during operation of the machine through pedestals. Parting plane joint of oil guard ring and duct should be feeler tight and no elongation of holes on these area may be permitted. The bearing parting plane bolt are to be tightened to required torque only no other method of tightening of these bolts may be used. Adjustment of shims between spherical/torus and bearing body is limited to +0.30 mm in up and down and left, right direction. this T1-08-0801G Page No. 66
Bharat Heavy Electricals Limited Rev 00, 7-98
Before deciding axial position of the bearing the axial position of the rotor is to be determined.10 mm may be permitted on front and rear pad sizes in exceptional cases. rear pedestal as a whole may be shifted axially to ensure correct position of the thrust bearing. Before fitting of pads in the bearing ensure that there dimension are made parallel to suit the front and rear slot size of the bearing (size between thrust collar and bearing body). • During alignment of rotor along the bearing with respect to the shaft by moving spherical seat of the bearing radially and axially. If necessary the H.P.15 mm.margin may be left for emergency work during overhauling of the machine any adjustment during erection and normal overhauling may be done by adjusting shims between spherical/cylindrical seat and pedestal base only. • Pressure proper fitting of babbitt metal liner in the bearing body including necessary pinch in the fitting of its liner. Install upper half bearing along with all pads and fix their axial keys. 7-98 . Ater fitting of pads in the bearing ensure their free movement over the bearing. Necessary dial gauges are to be installed on bearing during fitting of these keys. For left and right adjustment the complete pedestal of HP front and HP rear may be moved with the help of their radial keys. After ensuring the perfect alignment of the bearing the axial keys are fitted after assembly of upper half bearing. 67 • • • • • Bharat Heavy Electricals Limited Rev 00. The above discussed points were common for Journal bearing and combined thrust and journal bearing. T1-08-0801G Page No. • No elongation of holes are to be carried out in spherical sat of the bearing for the purpose of its alignment. • • • Align the thrust bearing in such a way that the thrust pad gap achieved are prallel and no difference are noticed in front and rear pad thicknesses.10/0. These axial keys are to be fitted in perfect parallel slots without any clearances. Movement in the thrust pad should be ensured and a difference in thickness of packers including shims should be with in + 0. After completion of axial key works of the bearing the thrust pads may be fitted in the bearing with a clearance of about 0. Install lower half bearing in position along with their pads and put very small quantity of oil on journal then rotate the rotor and put blue color on the thrust collar of the rotor on both front and rear side. Now some specific points are detailed here for the assembly of combined Thrust and Journal bearing: • Remove all the thrust pads before placement of bearing in position and store them in a proper place. The keys are to be fitted in such a way that there is no movement to the bearing during fitting of these axial keys.
• Before installation of thrust bearing along with thrust pads in position the both halves may be bolted out side and their pads may be checked for color contact over a surface plate also in front and rear both sides.• Rotate the rotor and move + direction axially with the help of wooden planks. Remove both halves of the bearing and see the blue contact on thrust pads. If necessary some cutting may be carried out on the pads to achieve the color contact.30 + 0. In spherical to spherical bearing the variation in contact if noticed can be corrected by matching/lapping at site. This exercise may be repeated few times to achieve the blue contact • Ensure a float of 0. In case of torus to cylindrical type of bearing if the contact are not satisfactory then the bearing and its seat may be remachined at works.10mm during color matching of the thrust pads. If necessary the minor adjustment of shims may be carried out in the bearing pads. Bharat Heavy Electricals Limited Rev 00. • During overhauling of the unit the bearing contact are to be rechecked and need correction. Sometimes the heavy pitting marks are also noticed on same of the bearing and these need correction by machining it. 68 . 7-98 T1-08-0801G Page No. This will reduce the time cycle while carrying out the color contact of the bearing with the rotor.
7-98 T1-08-0801G Page No.Bharat Heavy Electricals Limited Rev 00. 69 .
70 . 7-98 T1-08-0801G Page No.Bharat Heavy Electricals Limited Rev 00.
7-98 T1-08-0801G Page No. 71 .Bharat Heavy Electricals Limited Rev 00.
the manufacturer must be consulted. Note : Based on the readings of bump check. In this case the shaft is shifted in the “+” and “-” directions from its operating position and the dimensions with the shaft in limit position are measured using a depth gauge. 72of 40 . 7-98 T1-08-0802G Page No. axial position of the shaft wrt casing is not to be altered. If the deviations from the specified dimensions is greater then the permitted tolerances. Bharat Heavy Electricals Limited Rev 00. Note: Enter the measured values ( actual dimensions ) on the record sheet and compare them with the specified dimensions.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (BUMP CHECK) BUMP TEST The axial clearance check is determined after radial clearance measurement has been completed.
IP and LP casing are measured by actually by moving the casing radially at site while rotor is rotated by hand. 73of 40 . This is a very accurate and fast method of measuring the minimum radial clearance of any of the casing. Such facilities are not available in many other designs of machine and causes longer duration in erection and overhauling of the units. Bharat Heavy Electricals Limited Rev 00. The major variation in these reading may cause vibration in the machine and obstruction in barring gear operation etc. 7-98 T1-08-0803G Page No. The centering of casing may not be fully sacrificed in comparison of rolling test readings and a compromise between these two readings should be made.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (ROLL CHECK) ROLL CHECK GENERAL DESCRIPTION In KWU machine the minimum radial clearances HP. PROCEDURE ROLL CHECK OF HP AND IP CASING 1. After completing the alignment of rotors the casing alignments are carried out by roll check method but equal importance should also be given to the centering of HP and IP casing. The rolling test should be carried out in cold machine only. Alignment and coupling of HP-IP and LP rotors are to be completed before starting the rolling test of the casing in normal case but this can be done without coupling of LP rotor also.
Always use thick oil for rotation of rotor over bearing in absence of jacking oil system. During overhauling generally the jacking oil system is available and the rotation of rotors are achieved with the hand barring of the machine. Two pipes of about 1250 mm long along with a pin to suit the dia of periphery may be used for rotating the rotor shaft. 7. 6. 8.05 mm with the help of hydraulic jack and jacking screw. During erection of machine the turbine rotor are generally rotated by hand with the help of periphery holes on coupling. 4. Fix temporary radial and axial keys of the casing before rolling test of casing. 5.STEAM TURBINE 500 MW ERECTION 2. 9. During dialing on spigot a proper care should be taken that the dials are properly mounted over the fixture and the fixture fabricated at site is strong enough to give the correct readings.00 mm shims. All the four jacking screw of HP and IP casing are to installed along with dial gauges for monitoring of up and down. 74of 40 3. One number hydraulic jack on each corner of the casing along with a spanner on each corner for jacking screw are also to be made available. During the rolling test the temporary casing packers are to be fitted with about 1. During the rolling test of any one of the casing the same is lifted first on all four corners in a step of 0. 7-98 . These readings can be compared as per the factory protocol also. Bharat Heavy Electricals Limited Rev 00. HP rear IP front and IP rear spigot are also to be completed before starting of the rolling test. The point dial indicator may be used here for the better results of the dial readings. The rotor is also rotated manually side by side with the lifting of casing. and left and right movement of the casing. The initial jerk to the rotor is given by the help of crane and it is further rotated by these pipes through periphery holes of the coupling. Before starting the rolling check it should be ensured that the rotor shaft is absolutely free on manual rotation/hand barring as the case may be. The type oil may be servo cylinder 1000 grade (IOC) oil. CRITICAL ACTIVITIES (ROLL CHECK) Centering of the casing on HP front. The rotation of rotor and lifting of T1-08-0803G Page No. During manual rotation two persons are to be employed for this work and during hand barring only one person is enough.
As soon as the shaft becomes tight the lifting of casing and rotation of shaft is stopped and dial readings on front end are recorded.00 mm shims from each packer of the casing.05 mm and freeness of rotor is ensured. After this check the casing is brought back to its zero position in radial direction also. The average lift on front end of the casing is the bottom clearance on front end of the casing.05 mm. 7-98 T1-08-0803G Page No. Bharat Heavy Electricals Limited Rev 00.05 mm on all four corners. Immediately after this the final radial key of the casing are fixed and the locked of the casing are released for fitting of the final casing packers. After this the casing on front end is lowered by 0. After recording the up and down rolling test values the radial keys of the casing are removed and again rolling test for left and right direction are done similar to up and down. Repeat similar operation of rotating the rotor and lowering the casing on front and rear end for deciding the top clearance in front and rear end of the casing. During this process the radial dial on the casing are also installed. Before starting the rolling test in downward direction of the casing remove about 1. After completing the rolling test readings of one of the HP/IP casing in up/downand left/right direction the clearances are readjusted as required at site in radial direction by moving the casing with the help of temporary radial key or shims on the casing packers. The final spigot dial reading are repeated and confirmed with the earlier readings.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (ROLL CHECK) casing continued till it becomes little bit tight on the seals of the casing After this the casing is lowered by about 0. but kept the casing on hydraulic jacks and jacking screws on its original position. 75of 40 . In case it is still tight the casing is further lowered by 0. After recording the bottom clearance of front and rear end of individual casing the casing is lowered with the help of hydraulic jacks and jacking screws to its original zero-zero position. Now the rear end of the casing are lifted similar to front end and bottom clearance of rear end are recorded . On front end and the freeness of rotor is achieved. The casing is again brought back to its original position by installation of the shims back to the packers of the casing after recording the top clearances of the casing. After ensuring the freeness of rotor it is again rotated and casing is lifted simultaneously on front end till the rotor rotation becomes tight on seals portion of the casing. The casing is then locked on four corners and final dial readings of spigot are recorded on front and rear end.05mm and rotor is rotated again if it is completely free. In case the rotor is still tight on its manual rotation the casing is further lowered by 0.
76of 40 . 12. No inlet and outlet pipes are to be welded with the casing till completion of rolling test and installation of final keys and packer of the casing. Bharat Heavy Electricals Limited Rev 00. During rolling test of the HP and IP casing if the rotor is rotated over the jacking oil then the adjustment of readings are to adjusted for the lift of the rotor also. Four numbers 1. CRITICAL ACTIVITIES (ROLL CHECK) After doing the full rolling test and fixing of a final radial keys and packers of one of the casing the rolling test of another casing is done including the fitting of final keys and packers. 16. The spigot dial readings are also to be taken over the spigot of shaft seales. If any taper is left on final packers of the casing then these four packers may be made to similar taper also. 15. The horn drop readings are also to be checked after the fitting of final packer of the casing. In case of IP casing the roll test readings are to be taken with the IP front end rear shaft scales.STEAM TURBINE 500 MW ERECTION 10. IP front and IP rear casing are to be recorded for future reference in the protocol. 17. 13. After fitting of final keys and packers of the casing the final spigot dial values of HP front. 7-98 T1-08-0803G Page No. 18. Radial clearance of the casing are to be ensured with reference to the factory supplied protocol also. HP rear. Necessary offset in the radial clear-ance is also kept before fitting of final packers of the casing toward the lift of the shaft during operation of the unit.00 mm undersize packers for HP & IP casing may be made during erection and supplied to customers as T&P items for further roll test during overhauling of the unit. 11. 14.
STEAM TURBINE 500 MW ERECTION ROLLING TEST OF L.P. INNER CASING 1.
CRITICAL ACTIVITIES (ROLL CHECK)
The rolling test of L.P. inner casing is done similar to the HP or IP casing but both side joints of L.P. inlet bellows are kept free or bellow itself are not positioned at all, till completion of rolling test. But during overhauling the rolling test is done with already welded bellows. Rolling test of L.P. inner casing is done after the neck welding of condenser andstiffener pipes inside the condenser. This include the welding of stiffener pipes of L.P. casing and gusset plates also. After rolling test of the casing the final radial keys of the Gusset block and casing packers on all four corners are installed. Necessary offset in the radial clearances of the casing is also kept before fitting of final L.,P. inner casing packers. Radial clearances of the casing are to be ensured to the design values. In case of any variation the matter may be referred to the designers. If the rotor is rotated on jacking oil then the rolling test readings are to be adjuted for the lift of the rotor also.
3. 4. 5. 6.
Bharat Heavy Electricals Limited Rev 00, 7-98
T1-08-0803G Page No. 77of 40
STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (CATENARY AND ALIGNMENTS)
CATENARY AND ALIGNMENTS
General Description The catenary of the machine is very important for a turbine and Generator assembly to achieve proper alignment of various rotors and loading on their bearing. Any deviation may lead to various operational problem in the machine like high shaft vibration, high bearing vibration, high babbitt metal temperature of the bearing etc. To avoid these problems it is necessary to maintain the catenary of the machine during erection and subsequent realignment/overhaul of the unit. Many times it is observed that though the alignment of rotors are within limit but the catenary as a whole get deviated from the prescribed design value of the machine. In order to avoid such derivation a need is felt to devise a procedure which shall ensure rotors alignment alongwith proper catenary of the machine. During first few years of the operation of the unit the possibility to the disturbance of the catenary are much more due to settlement of the foundation frame. In each overhaul of the unit the catenary of the machine is to be corrected. The L.P. front and L.P. rear pedestal are directly grouted here without any separate base plate. As such any correction on lifting or lowering. These pedestals are not very convenient so if necessary the rotor may be lifted or lowered with respect to pedestal seal bore and required catenary may be achieved. In extreme cases these pedestals may be even regrouted during major overhauls of the unit to correct the catenary of the machine. Procedure
Install a bench mark plate near L.P. rear pedestal as height of the machine center line with the consultation of civil Engrs at site. A plate of 200 m.m x 300 m.m size with 20 m.m thickness machined/ground on top side may be welded over a I Beam or a channel in level condition. This plate is to be installed very carefully as this will be a future reference for setting up the all elevation of the machine. Record half bore error of all the four pedestals and confirm the readings with the factory records also. The half bore error may be checked in both upper half and lower half of the pedestal and same may be punched on both halves in left and right side for all future references of the machine. During alignment of pedestal at the time of grouting with conbextra cement set the height of the pedestals as per required catenary of the machine considering +value for the half bore error of the T1-08-0804G Page No. 78of 40
Bharat Heavy Electricals Limited Rev 00, 7-98
STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (CATENARY AND ALIGNMENTS)
pedestals. While setting the height of the pedestals it should be kept in mind that the height for the center of the pedestal bore are to be kept as per the catenary of the machine not the parting plane of the pedestal. 4. For better results four water level jar connected to each other with a polythene pipe may be installed on each pedestal. The D.M., water may be used here and leakage through polythene tubes should be avoided fully while making the connections. These jars may be fabricated at site by about 125 mm. dia pipe with a plate welded in bottom and then machined for better seating on pedestal base. The height of the jar may be kept as about 175 mm. A depth micrometer installed and clamped over a magnetic base is also required for measurement of the water level in the jar. The micrometer point is to be made very sharp by grinding it. Here the magnetic base of the 0-10mm dial gauge may be used. .During measurement of water level in the jar the micrometer is to be kept approximately in center of the jar. The micrometer along with the magnetic base to be transferred from one pedestal to another pedestal very carefully so there is no disturbance to the height of the micrometer. All the necessary care are to be taken during this measurement i.e. there should not be any air bubble in the polythene pipe and the polythene pipe should be kept as stationary. While finalizing the catenary of the machine these measurements are to be repeated 3-4 times in a day at different intervals to avoid any possibility of the error. The height of the L.P. rear pedestal is the reference point for setting the height of all other pedestal and L.P. base plates. The L.P. rear pedestal height is to be first made with the benchmark plate as per the center line of the machine with the help of water level jar. The benchmark plate is to be preserved for all future references. The catenary is to be counter checked after grouting all the pedestals as well as after final alignment of the rotors. The final value of the catenary may be worked out as center of the shaft on each pedestal bore after taking the final seal bore readings. The final catenary should match with the design value of the catenary otherwise a necessary correction may be carried out. After ensuring the required catenary of the machine the coupling alignments are to be made as parallel coupling. T1-08-0804G Page No. 79of 40
Bharat Heavy Electricals Limited Rev 00, 7-98
7-98 T1-08-0804G Page No. As such this gives an indication of indifferent loading of the casing. In horn drop test a drop is measured on an individual corner of the casing with the help of a dial indicator by removing the support of individual corner and then it is compared with the opposite corner.STEAM TURBINE 500 MW ERECTION 11. optical measurement method or a method by which direct journal heights are taken on each bearing in place of pedestal height. This is a very important check and may cause serious problem in operation of the machine like high vibration in the machine failure of barring gear in hot/cold machine. outlet and extraction pipe lines etc.e. CRITICAL ACTIVITIES (CATENARY AND ALIGNMENTS) The value of the catenary given over the drawing are theoretical value calculated by the designers but due to the human error in site measurements some time the correct coupling alignment are not achieved then an alternate method for checking of catenary may also be used i. obstruction during expansion of machine etc. The horn drop readings are very important in HP & IP casing. 80of 40 .e. First the proper horn drop readings are made without connection of any pipe lines and then the reading are taken after welding of all pipe lines on HP & IP casing. Bharat Heavy Electricals Limited Rev 00. For measurements of direct journal height a special fixture is to be fabricated and necessary information about it can be separately given by PS-TS if such necessity arises. As such the influence of these major pipe lines are notices on each corner of HP/IP casing by comparing the horn drop test readings. The horn drop test will indicate the quality of work during assembly/welding of pipe lines with the HP & IP casing. HORN DROP TEST General description By horn drop test the loading of the casing on each corner is determined. 12. first without connection of any pipe lines the horn drop readings are recorded then it is compared after welding of inlet. The horn drop test is repeated at various stages in individual casing i. In Russian design machine the value of direct dynoxmetre loadings are recorded in place of this horn drop test.
Immediately after the completion of the horn drop test these keys/shims may be installed back and centering of casing may be rechecked before further works. 3. 5. While recording the horn drop readings the casing must be absolutely free and even the radial and axial key of front and rear portion of the casing are either to be removed fully or these are to be made completely free by removing their shims etc. 7. After transferring the load of the rotor on bearing and ensuring the casing centering with respect to shaft the horn drop check may be carried out. Before taking the horn drop reading ensure that the enough clearance is available on front & rear portion of the shaft with their seals in the casing inside. After completing the centering of the casing the some may be lifted by 0. 81of 40 . Actually during this stage of erection only temporary axial and radial keys are fitted in the casing and even they carry some shims also. This will help in avoiding the touching of seals with the rotor during the horn drop test readings. Before making the casings free on axial and radial key portion the dial gauges are to be installed to monitor the movement of the casing on radial and axial direction. 20 mm on all four corners by providing shims. 6. 4. 8.STEAM TURBINE 500 MW ERECTION 1. In HP casing the initial horn drop test may be done even after fitting of breach nut assembly and HP exhaust elbow of both sides. 7-98 T1-08-0806G Page No. The load of shaft is also taken on transport device during this stage. Procedure CRITICAL ACTIVITIES (HORN DROP TEST) After placement of HP and IP casing on four temporary packers ensure that the each corner of the casing is loaded on temporary packer and if necessary the shims may be given on packer for loading of the casing. 2. No piping may be connected to HP & IP casing till initial horn drop readings are over. No adjustment on packer of the HP front and HP rear pedestals are to be carried out after taking the horn drop test of the casing In case if any adjustment is carried out on these pedestal packers then horn drop test are to be repeated again. The piping work should not be postponed for want of horn drop the only thing the last joint with HP/IP casing may be left free till completion of horn drop check. Bharat Heavy Electricals Limited Rev 00.
In case of IP casing no locking of any corner of the casing is necessary during the horn drop test. 12. A dial indicator is also to be installed on each corner of the casing for measuring the drop of the casing. During the horn drop test the individual packer of the casing is removed and the load of that corner is supported over the jacking screw of the casing.STEAM TURBINE 500 MW ERECTION 9. The comparison in horn drop value should always be made in left and right side only of an individual casing. 14. After initial centering of the casing the each corner packer may be fitted with a shim of about 1 mm. All the four Jacking screw and hydraulic jack on each corner of the casing are to be installed for the horn drop test readings. 15. CRITICAL ACTIVITIES (HORN DROP TEST) In IP casing the initial horn drop test may also be done after fitting of IP inlet pipe lower half assembly but this pipe of upper half casing should not be fitted till completion of the horn drop test. 13. for further adjustment during the horn drop test. No subtraction / addition in shim sizes from outside is done here and only the shims are adjusted from left to right or vise versa till equal loading are achieved in left/right side of individual casing. During the initial horn drop the best reading within 0. 82of 40 10. In case of HP casing the drop on rear end is so high that unless the casing is locked on diagonally opposite end the horn drop check is not possible. 7-98 . This is repeated for each corner of the casing. Bharat Heavy Electricals Limited Rev 00. T1-08-0806G Page No. Therefore while recording drop on HP rear end the front end of the casing diagonally opposite to it should be locked with casing clamp. The pedestal is also required to be locked on all four side with its sole plate with the help of the clamps. In case of variation in left and right side reading the drop is adjusted by + adjustment of shims from left to right side or vise-versa. Now gradually the jacking screw is also relieved with the help of hydraulic jack on that corner and drop reading is recorded.05/0. 11.06 may be achieved by fine adjustment of the packer shims. The sizes of these casing packers are recorded after completion of horn drop to avoid any confusion at a later date while fitting the final packers. While recording the horn drop readings the drop on each individual corner may be controlled with the help of Jacking screw so that during this test the casing is not touching with the shaft in gland portion of the seals at all and enough clearance is left there to avoid damage to the seals inside the casing.
Even some time it is necessary to cut the individual or more piping joint for correction of horn drop readings. And any adjustment in piping supports can be carried out only after disconnecting the pipe line with the casing. The horn drop readings are not taken for L. 20. 17. 21. 83of 40 . The variation in horn drop reading of left and right side of a casing may be permitted upto a difference of 50%. After completing the welding of all pipe lines with the casing . The horn drop reading for an individual casing may be recorded after the fixing of final packers also. inner outer casing due to its fabricated structure and the parting plane of the casing are leveled on four corner with the help of water level jar arrangements. These readings are taken along with its radial and axial keys of the casing.. During variation of horn drop reading no correction is to be made on casing packers by adjustment of shims etc.STEAM TURBINE 500 MW ERECTION 16. Bharat Heavy Electricals Limited Rev 00. During this stage exactly this can not be defined that how much variation is permitted on these values of horn drop readings. the horn drop readings are repeated again for comparison with the earlier readings.. The variation at this stage is caused due to the piping pull/push only so if any correction is required then the same may be carried out in piping joints and support etc. 19. But this variation will indicate the influence of the piping load on the HP/IP casing caused due to welding/connection of various pipe lines with the casing. The variation in horn drop readings are permitted as long as sufficient positive loading is there on each corner of the casing.P. But if any corner of the casing is fully unloaded/heavily loaded then there is no choice left and pipe lines are to be corrected by dismantling it and making again a free joint with the casing. If necessary a fine adjustment may be carried out at this stage to achieve correct value of the horn drop reading. CRITICAL ACTIVITIES (HORN DROP TEST) The final packers on HP & Ip casing are installed only after completing the rolling test of these casing. 7-98 T1-08-0806G Page No. 18.
No convexity is permitted on these coupling faces however a concavity of about 0. The higher swing check value may cause higher shaft vibration. After having general experience of number of 200 MW & 500 MW units. Bharat Heavy Electricals Limited Rev 00. 84of 40 2. Any compromise at erection stage may cause serious problem during operation of the unit and any correction becomes much more tedious a later stage. 7-98 . This can be done initially during erection with temporary coupling bolts on LP-IP coupling before reaming/honing of coupling. Before placement of Module/Rotor in position the coupling faces of all the rotors are to be measured for concavity/convexity of their coupling faces.03/0. In 500 M. a necessity is felt to measure swing check value on IP rotor front end also for better results during operation of the units. For example 200/210 M. KWU machine with Russian Generator and static excitation system the swing check values are measured on HP rotor front end only.P. In a multi rotor Turbine-Generator system it is essential to measure the swing check value in both extreme end and where the weight of the rotors are light. PROCEDURE 1. This is measured on opposite end of the coupling and at the free end of the rotor. This can be checked with the help of a thin rectangular light weight straight edge. During the machining of rotors in the works some tolerances are permitted by Designer's on the coupling faces of the rotor resulting to some swing check values. Any variation in swing check values may be corrected without any hesitation during erection of machine. In case of any variation the matter may be referred to manufacturing units.W. front end and on exciter rear end. After placement of individual Module/Rotor the coupling faces are to be measured for axial runout before taking up alignment of T1-08-0806G Page No.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (SWING CHECK) SWING CHECK GENERAL DESCRIPTION The swing check is the measurement of radial throw caused due to coupling face geometric form of the two rotor coupled together.04 mm is permitted. the diameter of the coupling and the length of the rotor. The correction may be carried out either by interchanging the coupling position or by correcting the coupling faces by scrapping/cutting in consultation of Designers. The value of swing check depends on axial runout of coupling faces. However it is recommended to keep the minimum swing check values for better results during operation of the machine. higher bearing shell temperature etc.W. The maximum swing check values permitted caused due to the above tolerance for different diameter and length of the rotor can be worked out from the enclosed graph. machine the swing check values are measured in H.
The HP rotor rear coupling face can be measured after placing it on both of its bearing.P. The tie rod of lifting tackle should be ensured for correct fitting of its spherical bearing and Molykote should be applied on these spherical bearing for their free movement. 10. Bharat Heavy Electricals Limited Rev 00. First IP-LP coupling is to be made with temporary bolts and swing check on IP rotor front end is recorded. During coupling with temporary bolts the higher plane of one of the rotor face is to be coupled with lower plane of another coupling face of the rotor. The IP rotor faces are to be measured after placing IP rear end on bearing and front end on lifting tackle. may be referred to Designer's before taking up further works. During swing check of IP rotor its front end is to be supported on lifting tackle without making any connection between HP-IP rotor. Similarly L. 11. 85of 40 4.02 mm. During checking of swing check measure radial movement of rotor on parting plane and rotate the rotor either on jacking oil with hand T1-08-0806G Page No. considering their axial runout/geometric form of the coupling faces. During swing check the lifting tackle are to be fitted properly. While recording swing check of HP rotor the front end of the rotor is to be supported on lifting tackle. After taking the load of the rotor on lifting tackle ensure that the rotor is not disturb radially due to fitting of lifting tackle. Any variation on axial runout on coupling faces for more then the 0. 9. 6. During coupling on temporary bolts the uniform tightening on all the four temporary bolts are to be ensured otherwise it will disturb the swing check value of the rotor. 3. These spherical bearing should not obstruct the movement of shaft radially during checking of its swing check value. rotor.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (SWING CHECK) various rotors. 8. 7. may be placed on bearing on its rear end and front end supported on lifting tackle. 7-98 . 5. After this only HP-IP rotor is to be coupled with temporary bolts and the swing check value on HP front rotor is recorded. After completing final alignment of various rotor they are to be coupled with temporary bolts.
16. Bharat Heavy Electricals Limited Rev 00. 12. 15. the indifferent tightening and non-sequential During checking of swing check readings. the initial few rotations are to be given to the rotor to avoid initial sag and then only the readings are to be recorded. Any variation in readings may be referred to the Designer's. Similar method is to be adopted while checking the swing check value of the exciter except the rotor is hanged on the suitable size of sling in place of the lifting tackle. While recording the swing check initially with temporary bolts for HP & IP rotor.T crane with thick oil on bearings. After ensuring the swing check values as per the graph with on temporary coupling bolts. The final swing check value of HP front rotor is to be recorded after fitting/ elongation of all the coupling bolts of HP-IP & LP-IP rotors. Avoid jerk during rotation of rotor while recording the swing check values. 7-98 T1-08-0806G Page No. For improvement of the swing check values. Any variation need correction of the coupling before reaming/honing of the holes. 86of 40 . the fitting of eight number temporary bolts are preferred in place of four bolts on the coupling. 13.O. the HP-IP and LP-IP coupling may be cleared for reaming / honing of the coupling holes. 14.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (SWING CHECK) barring or with the help of E.
STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (SWING CHECK) Bharat Heavy Electricals Limited Rev 00. 87of 40 . 7-98 T1-08-0806G Page No.
Before placement of module/rotor in position check and record the coupling hole and journal dia of the shaft.04 mm. and an additional check is also made at works/site to ensure that the geometry of the entire coupling surface does not deviate by more then the 0. 7-98 . The number of shaft mainly depend upon the rating of the machine. During the alignment of two coupling both are to be turned in same direction and by the same amount when the measurement are taken to avoid the influence of the axial & radial runout present in the shaft caused due to the machining. Here equal importance is given to the radial & axial alignment of stationary parts to avoid any rubbing during operation of the machine due to expansion of stationary and rotary parts. 4. The basic function of any coupling is to connect two or more shaft together to form a shaft assembly. The axial runout on the coupling face may not exceed 0. PROCEDURE 1. The coupling checks determines both the radial and axial position of the two adjacent coupling flanges relative to one another. for a particular machine. 88of 40 3. except the concavity on the coupling face which is permitted upto 0. Check spigot and recess of the coupling and ensure their fitting before placement in position.P. The radial and axial alignment of the various shafts are to be completed before their coupling and alignments are to be done in such a way that the entire shaft assembly follow the continuous deflection curve given over the drgs. Place the module/rotor in position and check the radial runout of journal and axial runout of the coupling faces independently of T1-08-0807G Page No. rotor sometime the coupling head are shrunk fit and remachined. During coupling of the two shafts it should be ensured that the no stresses are exerted as a results of the coupling each other shaft. A very high accuracy is required during manufacturing of these rotor shaft at works.02 mm. Check coupling faces for the concavity/convexity with the help of a thin rectangular straight edge before placement of module/rotor in position.02 mm. After completion of the alignment and coupling of the shaft the casings are aligned radially and axially.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (COUPLINGS & ALIGNMENTS OF ROTORS) COUPLINGS & ALIGNMENTS OF ROTORS GENERAL DESCRIPTION The coupling on turbine shaft are generally rigid coupling but in case of L. Bharat Heavy Electricals Limited Rev 00.03/0. The radial measurement are performed on the circumference of the couplings and the axial measurement are performed on outer most diameter of the coupling. 2.
Bharat Heavy Electricals Limited Rev 00. During final alignment only the axial gap values are checked at 90o on four places by rotating both the rotor together and average of these four reading are taken. Any variation may not be permitted here and matter may be referred to the designer's.IP & LP rotor are aligned together and then their couplings are made. For left and right adjustment the complete H. During initial alignment of HP/IP & IP/LP rotor the radial checks are generally done with the help of depth micrometer and axial gap are measured with the slip gauges. front and HP rear pedestal may be moved with the help of their radial keys. 8. 7-98 . The HP. 9.02 mm accuracy. 7. But during overhauling of the machine the adjustment may be carried out in these packers for correction of catenary of the machine.30 mm. The final packers of the pedestal and base plates are fitted before the grouting of the pedestal itself and here no adjustment is necessary during erection of the machine. 10. The margin of + 0.Gen coupling the radial dial reading are also taken. After completion of final alignment no adjustment of packers and keys etc are permitted on pedestals and bearing the T1-08-0807G Page No. 11.P. During checking of radial and axial runout of the shaft place H. The radial alignment reading along with axial gaps are necessary wherever the effective spigot are not existing in two couplings i.e. The radial and axial face runout on the shaft should be within 0. Avoid rotation of two shaft in their spigot. in case of LP . rotor on both of its bearing and IP/LP rotor one end on its bearing and another end on the lifting tackle. After fully completion of HP/IP & IP/LP coupling with tightening of their final bolts the complete shaft is cleared for Generator rotor alignment. During alignment of rotor make HP/IP and IP/LP coupling gap parallel. in height & left/right direction may be kept for emergency works only. 5. 89of 40 6. After completion of the radial alignment the rotor are inserted in their spigot even with some minor variation in their axial gap values. Any adjustment during erection and normal overhauling may be done by adjusting shims between spherical/cylindrical seat and pedestal base only.P. During alignment of shafts the adjustment of shims in bearing torus may be fully avoided.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (COUPLINGS & ALIGNMENTS OF ROTORS) each shaft. If necessary these may be rotated after taking out from their spigot.
15. 14.02/0. 18. The molykote should not be applied on T1-08-0807G Page No. After alignment couple the HP-IP & IP-LP rotors on temporary bolts. Before alignment/coupling position the two shaft adjustment to each other depending upon the higher and lower point of the shaft with respect to their axial face measurement values. 90of 40 13. During coupling of rotors two taper pins may be used for proper alignment of coupling holes so that there is minimum enlargement of holes are done at site during reaming/honing. 16. As for as possible ream/hone all the coupling bolts holes to same size. Record coupled runout of the rotor and ensure that the coupled runout is not more then 0. The HP-IP & IP-IP coupling may be cleared for reaming/honing after ensuring the runout and swing check values of the rotors. Each hole during honing should be checked for bananas shape with the help of a parallel ground straight pin of 0. All the coupling bolts are to be machined and ground by 0. No banana shape is permitted in any of the hole. 19. These reading are to be ensured within the design limit. 17.005 mm accuracy. Before coupling of rotor on temporary bolts record their spigot clearances by actually moving the rotor radially. Unnecessary enlargement of holes may be fully avoided during reaming/honing at site as this may cause serious problem at a later date during overhauling of the unit. Bharat Heavy Electricals Limited Rev 00. in any where in the journal as well as in coupling area.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (COUPLINGS & ALIGNMENTS OF ROTORS) final alignment of HP/IP & IP/LP rotors should be checked after fitting of all the final keys and packers of the pedestals. These bolts are to be fitted with thumb pressure only and no additional force is recommended while fitting these bolts. In case of variation the cause of the error may be identified and corrected before further work of reaming and honing of the coupling. 12.03 mm. A very thin layer of molykote may be applied on all the coupling bolts during their fitting.03 mm undersize then the hole dia. During erection IP-LP swing check on IP front and HP-IP swing check on HP front are to be recorded on temporary bolts.02/0.03 undersize. In exceptional cases only the variation in hole sizes are permitted. 7-98 . The hole should be made to 0.
20. After completing the coupling work the casing radial and axial alignment may be done. During tightening of coupling at any stage first tighten four bolts on 90o location. 23. Always tighten bolts in proper sequence with 180o opposite bolts. on coupling and journal of the shaft. In exceptional cases the 180o opposite bolts may be made of equal weight. During tightening of coupling the radial runout on journal and coupling may be checked at various stages during tightening of bolts. After final tightening of LP-IP and HP-IP coupling the swing check value on HP front rotor is to be rechecked. this may cause unnecessary stresses on the coupling. In case of variation in value a proper correction is to be made with consultation of designer's. These are to be balanced within an accuracy of 5 gms each along with their nuts. 21. These bolts are to be elongated to the value given over drgs. The final coupled runout should not be more then 0. The indifferent or unsequential tightening for achieving the swing check value or coupled runout value may be fully avoided. In case all these bolts are of equal size then their weight must be equal. Bharat Heavy Electricals Limited Rev 00. This may cause in breaking of their locking pin during elongation of coupling bolts. 22. 7-98 T1-08-0807G Page No.03 mm. 24.STEAM TURBINE 500 MW ERECTION CRITICAL ACTIVITIES (COUPLINGS & ALIGNMENTS OF ROTORS) seating face of the coupling bolts. All the coupling bolts are to be balanced before finally fitting/tightening in position. 91of 40 .
P.P. obstruction in expansion of the machine. the same can be cleared for welding of inlet and outlet pipelines.V. Similarly the Hot Reheat lines between two Hot Reheat strainer to the control valves and from control valves to the I. These pipelines are directly affecting the performance of the turbine during operation of the machine and a necessity is felt to fully involve the turbine Erection Engineer in erection / welding of the pipelines at site along with the Piping Engineers. CRH & HRH connections with HP & IP casing. only two ESV control valves are used in the system. casing.P. The piping connection between I. Present method of erection / welding much of the problems are not faced during operation of the machine. babbit etc.P. casing also need equal care during erection / welding of these pipelines.but in case of 500/250 MW HP Turbine the casing is supplied with four inlet flanges also. As such in 200 MW machines. control valves also.STEAM TURBINE 500 MW ERECTION Welding of steam inlet and exhaust pipe lines with HP and IP casing In 210 MW machine the HP Turbine is supplied with two inlet and two exhaust flanges for connection of the pipe line.P. Bharat Heavy Electricals Limited Rev 00. the I. casing need much more care during erection / welding of the pipelines.V. As such in 210 MW machines. Which may cause vibration in the machine.P.P. The inlet lines from each two control valves are joined together and make one connection with the I.e. if proper care is not taken during erection / welding of MS inlet.V. casing. higher babbit metal temperature and failure of brg.V.P. obstruction of barring gaer operation in hot / cold machine. cross around piping also need proper care but due to its construction with number of bellows in the system.P. casing in bottom. It may be either two ESV oontrol valves or four ESV control valves to cope with the design of the casing. during operation of the machine. After completion of the rolling test the installation of final keys and packers of the H.P. and I. The main steam inlet line from main steam strainer to the control valves and then from control valves to the H. a load will be transfer from the pipe line to the casing. control valves or four I. Whereas in 500/250 MW machines . Similarly in 210 MW machines. there can be either two I. In case. casing i. The 500 MW I. However if proper care is not taken here then that may cause the unnecessary loading on the various bellows of the piping and reduction in their life. casing but some time these are supplied with four numbers of I. casing is similar to the 210 MW I. casing is supplied with two inlet flanges and eight number exhaust branches or either two exhaust branches only along with two inlet flanges. only two I. control valves. control valves are used but in case of 500 MW machines. These eight number exhaust branches are distributed four on each side of the casing and each four branches are joined together with one common pipe while connected to L.P. 7-98 . casing to L.
After this all the three hangers of each valve are to be locked to avoid any movement of the valve in upward direction. These lines should be in perfect floating condition on their hangers before taking up the further work of MS & HRH lines upto the ESV & IV control valves. CRH. The ESV & IV valves are to be cleared after fitting of their servomotors and then levelling including the correct elevation etc. These lines are to be erected in such a way that both the end joints remain free and parallel with the strainer and control valve after taking their load on hangers. Now all the in between joints may be keeping the end joints 4. Weld MS & HRH lines with the strainers and again ensure the freeness / paralalllity of MS & HRH lines with the ESV and IV control valves. in case the equivalent insulation weight is removed or any of the servomotor is removed. 7-98 . HRH pipelines with HP & IP casing and control valves / strainers. Erection and welding of MS line upto MS strainer and HRH strainer are to be completed first including either their insulation or equivalent weight is to be given for their insulation weight in the lines. The change in hanger value of the control valve is to be adjusted back by lifting the valve with the help of hangers. The HP & IP casings are to be cleared in all respects after fitting of final packers and axial / radial keys of the casing. 6. 5. 2. Any minor variation may be readjusted on hangers to obtain the freeness of the joints with the control valve. Install MS & HRH lines between strainer and control valves and weld all the inbetween joins of the pipelines except the end joints with the valves and strainers. 3. 7. Install the MS and HRH lines between control valves and HP /IP casing .STEAM TURBINE 500 MW ERECTION PROCEDURE The following points are to be taken care while welding MS. Bharat Heavy Electricals Limited Rev 00. The equivalent insulation weight is to be given on each control valve befor connection of any pipeline with the valve. The freeness of joints are to be ensured after giving the equivalent insulation weight of the lines. Before starting of any welding with the control valve the valves are to be locked for their movement. The control valve hanger reading should remain same as before and after installation of equivalent insulation weight on the valve. 1.
The equvalent insulation weight is also to be given on these line while checking the freeness of end joints with the HP casing. similar to MS lines but before weling of these line the inbetween joints are to be completed first . The left and right side casing joints are to be welded together . SPECIAL CARE Bharat Heavy Electricals Limited Rev 00. 9. Similar proceedure may be followed for the lines between I V valves and IP casing also. The equivalent insulation weights are also to be added during erection of these pipe lines before welding the end joints. during welding the left and right movements of casing may be monitored by installing the radial dial gauge on the casing. The CRH lines are to be erected on their permanent hangers and the joint with the HP casing are to be made free /parallel after floating the pipe lines. 10. the same may be welded together.STEAM TURBINE 500 MW ERECTION free with the valve and the casing. 7-98 . 11. 8. The erection of these lines are to be done in such a way that freeness and parallelity of end joints are achieved after fully floating the pipe lines on their hangers. Weld left and right MS and HRH joints togethers with the HP and IP casing to avoid any left and right loading on the casing . The horn drop readings are to be recorded for both HP and IP casing after copletion of the job including insulation of pipe lines and control valve etc. But the stress relieving of all the in -between joints of the lines are to be completed before taking up work of the above last two end joints . After ensuring the freeness and parallelity of the end joints between ESV control valve and HP casing .
The steam blowing of the MS and HRH pipe line are to be carried out after fully completing the erection /welding of lines from control valve to the HP and IP casing . 6. The readings are to be measured in the following stages :− After complete leveling of ESV and IV control valves with their servomotors − After putting the equivalent insulation weight on the control valves. 3. If the above condition are fulfilled then there no need of any locking of the valves during the welding of any pipe lines. − After connection of MS & HRH lines with the HP & IP casing . This may be taken care while erecting the HRH lines. The control valves hanger readings are to be measured with the inside micrometer in various stages and changes are to be monitored properly . If possible keep the insulation weight and servomotors on ESV and I V control valves during erection /welding of these MS & HRH lines from strainers to the valve and casing . Proper care is to be taken during erection of these lines to avoid entry of foreign material. All the four corners of the casing may be locked with the casing clamp during welding of piping joints to avoid movement of casing radially. 2. Bharat Heavy Electricals Limited Rev 00. 7-98 . Ensure proper clraning of MS and HRH lines between controls valve and casing as these lines are not covered in steam blowing operation . 5. 4. The load of the upper half HRH pipe upto the flange supplied by turbine supplier is taken by the IP casing and by the piping hangers.STEAM TURBINE 500 MW ERECTION 1. − After complete insulation of control valve and pipings. − After readjustements of control valve height equivalent to insulation weight. − After connection of MS &HRH lines with the strainers .
The spring units for all the above TG foundations are supplied by M/s GERB which they call the GERB vibration isolation system for TG foundation. In BHEL . Dahanu 2 x 250 MW. Bharat Heavy Electricals Limited Rev 00. Suratgarh 2x250 MW . we have yet to satisfy fully ourselves about the advantages of this system after getting the feed back from various machines under operations with spring loaded foundation though the advantage claimed by M/S GERB are listed below: 1. Trombay 1x500 MW.STEAM TURBINE 500 MW ERECTION SPRING LOADED FOUNDATION The spring support for TG foundation in our country is a new development though some of the machines are already in operation with spring loaded foundation at various power stations.0 REDUCTION IN BASE MAT SITE AND ITS COST : The vibration to the main column are isolated by the spring element resulting to small size base mat which reduces the construction cost and time. Most of TG foundation built in Germany in last 20 years are spring loaded foundation. Unchahar 2x210 MW and Vindhyachal 2x500 MW. 7-98 . Similarly the machines which are going to come with spring loaded foundation with BHEL equipment are Chandrapur 1 x 500 MW . The various machines in operation with BHEL supplied equipment and spring loaded foundations are Dadri 4x210 MW .
Bharat Heavy Electricals Limited Rev 00. 3. 7-98 .0 EARTHQUAKE PROTECTION : Machine will have more steadiness and stability in the event of earthquake compared to normal foundations. 4. so that the total number of columns are reduced and the space to accommodate more equipment is increased.0 SUBSEQUENT TUNING OF THE FOUNDATION : It is possible to tune the foundation subsequently by replacing the spring elements having different load capacity of the springs.STEAM TURBINE 500 MW ERECTION 2. 5.0 REDUCTION IN NUMBER OF COLUMNS: The same column of TG deck may also be used to support surrounding floors at the building .0 EASY HANDLING OF SETTLEMENT PROBLEMS: Excessive settlement of column can easily be adjusted by inserting or removing shims in spring units. This results in more rigidity of building structure of surrounding floors and further in cost saving.
00 mm additional compression and which are removed at the time of loosening of the spring elements before final alignment of the machine. The required pretension of the spring units are done at site before its installation in position.00 mm is left between cover plate and spring units for settlement of deck during casting. A special device for pre-compression of these springs units is also supplied by spring supplier.00 mm. that all the major parts of the machine are installed and condenser have been filled upto operating water level including CW pumps in operation for full load condition of the machine. These additional shim are removed in minimum two stages after ensuring. Each spring unit is provided with 10. Similarly the resistance pad is given on top of the steel shim to avoid the shifting of the shim during operation of the machine. The shuttering of RCC slab of TG deck is furnished before installation of these spring units.00 mm is sufficient for this purpose. The filling procedure of visco liquid is explained separately by the spring supplier. The top surface of individual column where these spring units are mounted should be within accuracy of +00 mm to -3. If necessary these may be corrected by chipping before installations of the spring units.STEAM TURBINE 500 MW ERECTION INSTALLATION OF SPRING ELEMENT: The spring element in 500MW machines and further higher rating machines are used with visco dampers. After lowering the spring unit the cover steel plates are placed in position with shuttering supports.00 mm to 10. Each spring units are placed over the resistance pad to avoid movement of the spring units during operation of the machine.00 mm of steel shim for future adjustment. During installation of spring units. 7-98 . The visco dampers are also filled up at site only with visco liquids supplied by spring supplier. Refer section “Releasing of TG Deck Spring” for removal of additional shims.00 mm in total including individual column variation of +00 mm to -3. Bharat Heavy Electricals Limited Rev 00. additional shims are provided for this 5.00 mm. The springs units are not supplied to site with required pre-tension values through these are supplied with some amount of pre-tension.00 mm shims from each spring unit and the same may vary from spring unit to spring unit depending upon the variation of column level/elevation and variation in level of spring cover plate etc. It is also not necessary to remove this complete 5. The spring units are not only pre-compressed for dead load of the machine but it is further pre-compressed to prevent the loosening of the spring during installation of the equipment due to unforeseen additional loads. An air gap of about 5. If major variation in calculation of load over the spring units are not expected then an additional compression of 5. The bottom shuttering of pedestal must be cut over the column head for lowering the spring units. The level deviation among various columns is permitted +00 mm to -5.
an equal air gap between 5 . The radial alignment of HP. rolling test of all these casing are also to be carried out after final alignment of rotor and with the CWP in operation etc. Many time it is not possible to wait till completion of all the works on Turbine Generator area as required for final alignment of all the rotors for reaming / honing of the various coupling. All the pipe lines connected with the Turbine and Generator should be made available on permanent hangers and supports to avoid any additional load on the TG deck afterwards.e.STEAM TURBINE 500 MW ERECTION RELEASING OF TG DECK SPRING The TG deck springs are released after installation of all Turbine Generator components including piping and the condenser has to be filled up to operating level including CW pump in operation for full load condition.the coupling may be opened and realigned. After realignment . IP and LP casing i. The coupling bolts need not be elongated at this stage and once all other works are ready for final alignment of rotors . the coupling bolts are to be fitted without any further reaming / honing of the coupling holes.e.00 to 10. 7-98 . No adjustment of TG deck springs or condenser springs are permitted after final alignment of the rotors. The insulation of various casing / pipe lines including cladding if any are also to be installed otherwise the equivalent weight is to be incorporated before release of desk spring. The TG deck should also be made free all.00 mm only.00 mm is left between all the springs and bottom of the steel cover plate. i. the final alignment of various rotors and turbine casing are done after release of the spring unit.around to avoid any obstruction in its movement. In such cases without releasing of the spring units the alignment of all the rotors can be done and reaming / honing including fitting of all final coupling bolts can be completed. Afterwards TG pedestals are placed /aligned and their elevation are maintained as per required catenary of the Bharat Heavy Electricals Limited Rev 00. After placement of TG deck springs in locked condition with shims and resistance pad etc. Similarly the condenser spring measurement should be with in + 1. The form work and support of TG deck are removed once the concrete has hardened sufficiently. During any subsequent adjustment of TG deck spring the final alignment of all rotors are to be checked. This is generally done after 28 days of casting of the deck and all load of deck is transferred over the spring units . During release of TG deck springs and final alignment of rotors the condenser spring is also to be kept in floating condition considering that condenser neck welding is already done. with similar conditions of final alignment of rotors. The shims provided for additional compression of the spring units are also adjusted during this stage. The Generator hydrogen cooler & LP heater if any inside the condenser are to be filled up in cooling water space for their operating condition before release of TG desk spring. The exact value of air gap can be determined by the civil engineer depending upon his experience but generally it is between 5.00 to 10.00 mm otherwise the shims may be adjusted in condenser springs.
00 mm is possible in spring Units. Certain minor variations on height of the spring units are permitted . Bharat Heavy Electricals Limited Rev 00. During releasing of TG deck spring while this additional 5. The sizes of the shims are also recorded for each spring.00 mm shims (for additional compression) are removed the catenary of the machine is to be achieved within + 0.STEAM TURBINE 500 MW ERECTION machine before grouting the pedestals with the non-shrinking cements . Any minor adjustment for alignment may be done on bearing if it is in permissible values and margins is available on the bearings seals bores. The ready-made galvanized shims are also supplied in required sizes alongwith spring unit in 3. During realignment of machine in subsequent overhauling the `catenary of the machine are to be checked and if necessary the shims of the springs are to be adjusted to achieve the correct catenary or at least to the old values . 1&4 with the help of TG deck springs by adjusting the shims and afterwards only the rotors alignments should be taken up. 7-98 . After finally release of TG deck spring and with water in condenser hotwell upto operating level including CWP in operation then spring heights are measured on four corners for all future reference. The catenary checking and alignment of rotors may be done together but all major adjustment for correction of catenary is to be done by adjusting the shims of the spring units. if it is required for achieving the Catenary of the machine. Any minor variation in catenary left after releasing of TG deck spring may be adjusted in the spherical/cylindrical seat of the bearings for achieving the correct alignment of the shaft. A bench mark may also be preserved on TG floor as reference for LP rear pedestal parting plane height for all future reference.00 mm and 2. The TG deck spring shims are adjusted with the help of hydraulic jacks. Either two/four numbers hydraulic jacks are used for this purpose which are supplied by the spring supplier. The height of TG deck spring are taken on four corners near the springs. These hydraulic jacks are group operated type and works with one pumping unit which is electrically operated.20 mm bearing No.00 mm thickness so an adjustment of upto 1. Similar methods are used for release of the spring locking bolts also. Here some punch mark may be provided on all springs so that measurements are taken at the same place always.
00 mm than the necessary adjustment is to be carried out. The locking of springs can be avoided if water is filled up to required level and level is maintained during neck welding of the condenser.P. the spring height is recorded on its four corner and further they are pre-compressed for the value of welding shrinkage’s by an amount of 3. dome wall assembly and its stiffener pipe. The required pre-compression of the condenser spring can be done by filling the equivalent weight of the water in the hot well of condenser and then locking the condenser spring at that position. etc. During subsequent overhaul of the unit the condenser spring height alongwith TG deck spring height need a monitoring. During neck welding the complete height of L. As a general practice whenever the TG deck spring height are checked then the condenser springs height are also to be checked. After completing the neck welding and draining of condenser ( for equivalent value of the pre-compression of the condenser springs) the condenser springs height are recorded and if variation are noticed for more than +/. Bharat Heavy Electricals Limited Rev 00. Sometime during floating of condenser an additional weight of water is filled up in condenser depending upon the designer’s requirement. condenser is floated for welding with the Turbine. 7-98 . This can be done by adjusting the shims in the springs although if proper care is taken during the neck welding no such variation are noticed. The TG deck springs are kept in locked condition during the neck welding of the condenser. outer casing is installed in position.e. After installation of all the major components of the condenser the spring are released i. Further during floating of TG deck springs the condenser spring heights are also monitored and if necessary the shims may be adjusted on condenser springs to maintain the old values of the condenser spring at the time of floating of condenser. All the connected pipe lines of the condenser are to be ensured on permanent hangers before floating of the condenser. Before neck welding all the major components of the condenser are to be installed including its tubing .STEAM TURBINE 500 MW ERECTION CONDENSER NECK WELDING IN SPRING LOADED FOUNDATION OF 200/250/500 MW KWU DESIGN MACHINE.P.00 mm depending upon the designer requirements. inner and L. During floating of the condenser it is to be ensured that condenser is free all a round and none of the pipe line are obstructing the movement of the condenser. water boxes.1. The condenser neck welding is carried out as per the backstep method for which the procedure is laid down in KWU manual of steam Turbine assembly sheet No 1-2-6330-0001/1. After floating the condenser.
STEAM TURBINE 500 MW ERECTION
ERECTION OF PIPING
NOTE: These guidelines are intended to provide advice to lay and support pipings at site, especially non-prefabricated pipes < Nb 50. GENERAL These guidelines apply to turbine and generator piping forming part of the BHEL scope of supply and delivered to the site in the form of prefabricated pipe sections and straight lengths of piping. Generally Applicable Specifications Prefabricated lines > Nb 50 In case of deviation the site erection engineer to decide in alternate routing. LAYING OF PIPES WITH ROUTING SPECIFIED IN PIPING PLAN. 1. 2. 3. 4. Lay the lines as specified in the piping plans. Support them at the defined points. Cold bending method and special pipe-bending equipment should be used for bending of pipes. Care should be taken to ensure that the deformation is well within the tolerance limits.
ACCOMMODATION OF MOVEMENT AND EXPANSION. 1. Care is to be taken to ensure the movements at pipe terminals and thermal expansion of the pipes themselves are
Bharat Heavy Electricals Limited Rev 00, 7-98
STEAM TURBINE 500 MW ERECTION
accommodated by adequately long legs and expansion loops. 2. For lines connected to emergency stop valves (main steam valve, stop valve, bypass valve ) allowance of ± 20 mm in all directions shall be made. Determine with the aid of the diagram (Fig. 1 & 2 ) the pipe legs required to accommodate terminal movement and thermal expansion. Ensure the valid coordinate system of that power plant (Fig 13) is adhered. If it is not possible to obtain values for movement of the terminal point taken from Fig 14, add a 50% safety margin to the thermal expansion calculated for the connecting pipe Figs 3 & 4.
3. 4. 5.
ASCENDING AND DESCENDING GRADIENTS 1. 2. 3. PIPE SUPPORTS 1. Pipe supports should not restrict pipe movements. Where springloaded supports are used, the additional load or load relief exerted by spring force on the pipeline at maximum deflection from its unloaded position should not exceed 25% of the supported pipe weight. (Fig. 6). The Table (Fig. 5) gives reference values for pipe supports. When fabricated pipe supports and guides, only flat steel pipe clamps and aluminum clamps serve as the pipe bearing surface. Install all lines with the ascending or descending gradients appropriate to their function. Lay supply lines with a constant ascending or descending gradient at least 5 mm/m - with at the very least a 5O slope (-90 mm/m). Lay drain and vent lines with a descending gradient of a least 20 mm/m.
4. The use of round -steel shackles should be avoided in all cases. ATTENTION: Suspension supports are to be preferred to support from beneath. Friction points should be avoided.
Bharat Heavy Electricals Limited Rev 00, 7-98
STEAM TURBINE 500 MW ERECTION
WELD PREPARATIONS AND WELDING OF PREFABRICATED AND NON-PREFABRICATED PIPES.
WELD PREPARATIONS 1. 2. WELDING 1. 2. 3. Complete welding as per WPS/drgs. Nitrogen purging to be done wherever required. Complete N.D.T. Ensure proper edge preparation as per drgs. Remove scale, rust, paint etc. from weld joints.
Bharat Heavy Electricals Limited Rev 00, 7-98
7. lay jacking oil lines so as to be protected by other lines of larger nominal diameters against being used as an aid to climbing. 5. Other matching and welding work to be done when the bearing pedestal is full assembled. A drain loop at the lower end of this line upstream from the blowers return drains to the oil tank. weld and examine the prefabricated connecting pieces of the discharge and suction nozzles prior to the final erection of the first bearing pedestal. 8. 9. fit a protection plate to protect the line in this area. Fire Prevention To avoid fire hazards. 6. The direction of flow of the oil temperature control valve should be ensured as indicated by markings on the valve itself. Jacking Oil Lines 4. do not route oil lines near lines or components at high temperature. Once the line has been welded to the bearing pedestal.STEAM TURBINE 500 MW ERECTION SPECIAL SYSTEM REQUIREMENTS Lubricating Oil System 1. 7-98 . 2. Bharat Heavy Electricals Limited Rev 00. 3. Oil Vapor extraction lines Ensure that oil vapor extraction lines are laid with a gradient descending constancy towards the main oil tank without low points. Where possible. Match up.
They do not include : turbine start-up and auxiliary start-up oil lines. 7. pilot fluid line (between pressure transducer and pilot valve on Nb200 and Nb250 bypass stop valves with LP hydraulic system). ensure that no detachable connections or valves are erected directly above hightemperature lines or components. test and return fluid lines. Version 4. auxiliary trip. secondary auxiliary secondary and bypass signal fluidlines. and water filled (condensate-filled) impulse lines. Fig. each high point must be provided with permanent venting facilities (orifices with a diameter of 1. If a line is installed from the control equipment to the load with a descending gradient (ascending gradient counter to the direction of flow) there must be a minimum gradient of 175 mm/m Fig. If local conditions make it impossible to observe the 10OC minimum gradient in installing a line as shown in Version-2. A number of different routing strategies are available for this purpose (the control medium flows from the control equipment) Fig. Control Fluid System Single Fluid Lines 11. These includes : primary oil lines.5mm).8) Version 3. 7-98 .STEAM TURBINE 500 MW ERECTION If the laying of oil lines in these areas cannot be avoided. If it is not possible to install the line as shown in Version 1&2. If local conditions make it necessary to install the line with one or more high points. Version 2. 13. 12. by[pass startup fluid lines.8. 7. trip. almost all fluid lines which do not lead directly from pump via filter to component). lay them with an adequate ascending or descending gradient to prevent air pockets from forming and accumulating. Signal fluid lines comprise all those lines in which some kind of signal or pulse is transmitted from one point to another (in other words. To ensure correct functioning of signal fluid lines. 10. Version 1. If a line is installed from the control equipment to the load with an ascending gradient (ascending in the direction of flow) there must be a minimum gradient of 67 mm Fig. two other strategies may be adopted (Fig. then reduce the Bharat Heavy Electricals Limited Rev 00. 7.
e. In laying these lines. i. provide sufficient compensation for thermal expansion. As the flow is generally directed via the installed orifice plate. Ensure that the lines are concentric within the penetrations to accommodate the insulation to be installed subsequently.8. Bharat Heavy Electricals Limited Rev 00. These pipes expand by approximately 6 mm/m between the cold state (initial temperature 20OC) and the hot state. If the system flow chart indicates that the damping device should be installed as shown in Fig.9 the flow passes via the orifice plate (slow flow) if the damping device is to be installed the other way around the ball is lifted away from the seat and thus permits a rapid through flow.STEAM TURBINE 500 MW ERECTION gradient required from 175 mm/m to 67 mm/m by introducing an external supply to reverse the direction of flow Fig. The service temperature for all lines can be assumed to be approximately 450OC. though the pipe penetrations in the LP end walls before mounting the LP bearing pedestals. 1. Connect the lines up when the LP steam seal casings have been fully assembled. The as-installed configuration of each damping device is indicated in symbolic form on the system flow chart. care must be taken to interpret the symbol correctly. SEAL STEAM SYSTEM Seal Steam Lines. 7-98 . Installation of Damping Devices 14. Leak-Off and Seal Steam Extraction Lines in the Steam Seal Casings. pressing the ball downward against the valve seat. valve Stem Steam Leak-Off Lines and Seal Ring Steam LeakOff Lines. ATTENTION : Always include a safety margin. Insert leak-off and seal steam lines. 2. 1.
in which two Nb 25 nozzles are welded. 3. From this pipe leg. observe the following: Bharat Heavy Electricals Limited Rev 00. All drain lines shall have as steep a gradient as possible. 2. NOTE: The header should not be insulated over the last 2-3m so as to ensure that all condensation takes place below the final connection to the transducers. Determine from the diagram (Fig.2) the minimum legs required to accommodate movement.12. ATTENTION : Always include a safety margin. erect two lines 500 mm long. 4. On drain lines made from thick-wall piping. GENERAL In laying these lines.12. 7-98 . with an ascending gradient from the terminal point to the pressure transducers. Lay the header. The service temperature in plant can be assumed to be approximately 450OC. making sure that the pipe leg below the transducers has a gradient of 30OC. DRAIN SYSTEM Drain Lines 1. PRESSURE SENSING LINES.STEAM TURBINE 500 MW ERECTION Pressure Sensing Line Terminals for the Seal Steam Control system 1. 2. provide sufficient compensation for thermal expansion. to the pressure gauge cutoff valves of the pressure transducers. ensure straight pipe sections at least 500 mm long between the drain sockets (on casings and pipes) and the first bend in the pipe. These pipes expand by approximately 6mm/m between the cold state (initial temperature 20 OC) and the hot state. Erect the pulse lines to the pressure transducers in a manner which will prevent the generation of fluctuating pressure pulses. 3. In erecting these lines. Refer Fig. an all cases at least 20 mm/m. Fig.
7-98 . Locking Devices for Threaded Connections. control fluid and drains system on account of the minimal terminal movement there. 5.STEAM TURBINE 500 MW ERECTION 1. 4. Lay pressure sensing lines such that the primary cutoff valve forms an anchor point. A compensating leg extending 1 meter in each of two planes should be provided in the lubricating oil. 2. 10 & 11). which entails laying the line between the connection point and the primary cutoff (anchor point) with the sufficient flexibility to accommodate movement of the connection point. All Fasteners should be locked using tab washers or a suitable thread lock adhesive. (Refer Fig. Bharat Heavy Electricals Limited Rev 00. 3.at least 1:15 (67 mm/m) between their connection point and the transducer rack. Lines under pressure must be laid with a constant descending gradient. Lines under vacuum must be laid with a constant ascending gradient. The above lines must have an adequate gradient .
STEAM TURBINE 500 MW ERECTION DESCRIPTION OF THE COORDINATE SYSTEM 1. A minus sign prefix shall be used to indicate the opposite direction. 7-98 . an indication of the three orthogonal axes X. Y and Z as in Fig. Projections of these axes in the corresponding drgs. When isometric are drawn of piping. shall be as under : X axis = view toward generator Y axis = view upward generator Z axis = view to the right This axis designation shall be positive where no prefix is used. Bharat Heavy Electricals Limited Rev 00. 3.3 is required. 2. 4.
20.E. Bharat Heavy Electricals Limited Rev 00.25 AND 32.094 cal/cm-secoC Specific heat -do= 0. SEPARATE HEATING DEVICE IS REQUIRED FOR EACH HOLE SIZE OF HEATING HOLE IN THE STUD I. A MINIMUM CLEAR HEIGHT OF 600 MM ABOVE THE CAPNUT IS AVAILABLE FOR INSERTION AND REMOVAL OF THE HEATING DEVICE. SCOPE OF WORK This specification covers the broad guide lines on design.001 cal/kg-oC Coefficient of linear expension = 13x10-6 OTHER REQUISITE DIMENSIONAL INFORMATION FOR EACH HEATING HOLE SIZE IS FURNISHED BELOW. FUNCTIONAL REQUIREMENT AND DESIGN INFORMATION: SPECIFIED ELONGATION OF THE STUD TO BE ACHIEVED WITHIN 15 MINUTES. Scope of supply also covers associated compressed air piping including a fine regulating valve. This heating causes elongation of the studs and then the capnut of corresponding stud is screwed down by a specified amount in hot condition to provide a calculated joint pressure in cold condition.STEAM TURBINE 500 MW ERECTION APPLICATION This device is used during heat-tightening of cylinderjoint bolts/studs of steam turbine to a predeterminedjoint pressure. Source for compressed air shall be made available. DESIGN SHOULD ENSURE THAT VENT HOLES FOR RELEASE OF HOT GASES IN OUTER TUBE REMAIN OPEN TO ATMOSPHERE IN ALL OPERATING CONDITION.2 PROOF STRENGTH IS 70 T/MM2 Thermal conductivity of above materials = 0. MATERIAL OF ALL THE STUD IS SAME 1 1/4 CR MO 3/4 V TIB. Similarly oxy-acetylene cylinder with heating torch not covered under this scope. 7-98 . A measuring device for measuring the extension of stud/bolt due to heating is also included in the scope of supply. pressure gauge & pipe fittings. manufacture and supply of gas heating device for the above mentioned purpose. Heating process is carried out by sending hot oxy-acetylene gases mixed with compressed air into the holes provided in the bolts stud. THE 0.
1 showing general arrangement of gas heating device and fig No.M. MASS OF HEAVIEST PIECE D3 STUD GAUGE LENGTH FOR WORKING ELONGATION ELON GATIO N OD x TH LENGTH DIA DIA 20 25 32 190 330 565 160 230 530 16 x 2.STEAM TURBINE 500 MW ERECTION ALL DIMENSIONS IN M.9 25 x 2. SUITABLE CHAMPING DEVICE FOR HOLDING THE OXYACETYLENE TORCH DURING HEATING PROCESS SHOULD BE PROVIDED. OXY-ACETYLENE TORCH IS IGNITED OUTSIDE AND THEN IT IS INSERTED IN THE HOLE MEANT FOR IT IN THE INLET CHAMBER.90 FUNCTIONAL DESIGN A typical outline sketches fig. CATALOGUE. HEATING SHOULD BE POSSIBLE IN ANY OF THE STUD IN ASSEMBLED CONDITION. STANDARD TORCH SIZES SHOULD BE SELECTED FROM THE INDIAN OXYGEN LTD. No. STU D HOL E SIZE LENGTH OF HEATING HOLE LEHGTH HEATING TUBE DIMENSIONS IN SIDE STUD APPROX.9 49 71 79 35 39. 7-98 .measuring device are enclosed for reference purpose. 2 .32 0.5 42 20 25 32 36 46 46 5 Kg 45 KG 85 Kg 185 325 560 0. HEATING SOURCE IS OXY-ACETYLENE GAS. THIS HEATING DEVICE IS A PORTABLE UNIT.53 0.9 20 x 2. Bharat Heavy Electricals Limited Rev 00.
THE DIFFERENCES OF THESE READING GIVES THE ELONGATION ACHIEVED. COMPRESSED AIR INSCRIBES THE OXY-ACETYLENE FLAME AT THE EXIT FROM INLET CHAMBER AND LED TO A MIXING CHAMBER. A PROPER AIR PRESSURE ENSURE THAT GAS MIXTURE REACHES HOLE BOTTOM WITH A REASONABLE VELOCITY OF HOT GASES INTO ATMOSPHERE FROM SAFETY CONSIDERATION. AND THEN AFTER HEAT TIGHTENING AGAIN IN COLD CONDITION. THIS GAS-MIXTURE TRAVERSE BACK THROUGH ANNULUS PASSAGE BETWEEN OUTER TUBE & HEATING TUBE & RELEASED TO ATMOSPHERE THROUGH VENT HOLES IN THE OUTER TUBE. AFTER IMPARTING THE HEAT TO THE STUD. 7-98 . IN ELONGATION MEASURING DEVICE INCLUDES A SIMPLE MEASURING ROD. Bharat Heavy Electricals Limited Rev 00. END OF HEATING TUBE KEPT AT A REASONABLE DISTANCE FROM END OF HOLE IN THE STUD. READINGS ON THE DEPTH GAUGE SHOWING LENGTH IF STUD ARE RECORDED IN COLD CONDITION BEFORE START OF HEATING PROCESS.STEAM TURBINE 500 MW ERECTION A COMPRESSED AIR PIPING OF SUITABLE SIZE IS FIXED TO INLET CHAMBER. A FINE REGULATING VALVE ON COMPRESSED AIR PIPE LINE IS PROVIDED TO REGULATE THE COMPRESSED AIR PRESSURE AND DAME IS TO BE READ ON CIRCULAR PRESSURE GAUGE WITH A RANGE 0 TO 20 ATA. A SLEEVE AND A DEPTH GAUGE. FROM MIXING CHAMBER HOT GAS MIXTURE IS LED TO HEATING TUBE THROUGH IS BOND. HEATING TUBE IS HELD CO-AXILLAY IN THE STUD HOLE.
7-98 . DEVICE SHOULD BE EASY TO INSTALL ASSEMBLE AND DISSEMBLE. I. DEFECTS TO BE RECTIFIED. MECHANICAL DESIGN: THE SOLE RESPONSIBILITY OF MECHANICAL DESIGN RESTS WITH SUPPLIER CONSTRUCTION OF THE DEVICE SHOULD BE ROBUST TO WITHSTAND THERMAL CYCLING AND THERMAL STRESSES. Bharat Heavy Electricals Limited Rev 00.S.STEAM TURBINE 500 MW ERECTION MATERIAL OF CONSTRUCTION While selecting the material for different components of heating device due considerations to its operation at elevated temperature.S 3073-67 RESPECTIVELY. 2102-1962 MEDIUM.S. It is customary to use allow steel (CR-Mo-V or CR-Mo) to provide long life to these component. DUE PRECAUTION TOWARD OPERATIONAL SAFETY MUST BE TAKEN. FITTING AND SURFACE FINISH SHOULD BE AS PER I. WELDING IF USED ANYWHERE IN ASSEMGLY SHALL BE CHECKED FOR CRACK & DEFECTS. depth gauge & sleeve material should be hardened and tempered. Measuring rod. 2709-64. DIMENSIONAL ACCURACY. high temperature gradient and thermal cycling to be taken into account. I.
The hole in the inlet chamber for insertion of heating torch should match with the standard torch shapes of Indian Oxygen Ltd.5 at a difference air pressure. 3. A clamping device to hold the heating torch should be provided.m. 5. Length of bass piece is 275 m.m. 2). 8. 4. A clamping device to hold the heating torch should be provided. Pressure gauge should be able to read the 0. Base piece is to have a flat circular and of 16 m. Extension piece length correspond to 130. Knurling should be done on each piece at one place. depth gauge and measuring rod.m. Depth gauge should have least account of 0. dia and other end should have female threads. 6. IN GENERAL. THREADING DONE SHOULD OF HIGH STANDARD FOR Bharat Heavy Electricals Limited Rev 00. 2. 7. 2. All threading corresponds to M10. 5. Measuring unit consists of sleeve. Measuring rod length may be made up in two pieces. 4. Depth gauge should be in general as per DIN 862. Measuring sleeve should have both faces parallel and flat. Compressed air unit should be removable and kept seperately when not in use. without leaving a large clearance or causing insertion problem. Length of sleeve should be chosen such that the difference dimension A & C is more than 150 m. Its scale must be case hardened. THERE SHOULD NOT BE ANY BURR LEFT ON ANY COMPONENT. and 370 m. Extension pieces should have threaded ends at both end. 7-98 . Compressed air system: 1.m. 3. (see if fig. Sleeve length C should be more than dimension LR.STEAM TURBINE 500 MW ERECTION Measuring Unit 1.05 mm.
valve supplier test certificate. Outer tube shall also be marked for the heating hole size. and operation manual should be submitted to EDM (ST) one month before final despatch of the equipment for approval. material test certificate. with its nomenclature. measuring sleeve shall bear on it. COMPONENTS SHOULD BE ELAMPED SUITABLY TO AVOID DAMAGE. FUNCTIONAL TESTING & ACCEPTANCE Supplier shall exhibit the suitability of operation of the heating device at BHEL works or at site (to be mutually agreed). 25mm or 32mm. calculations performed. On the inlet chamber the torch sizes (As per Indian Oxygen Ltd. shall be punched. catalogue) to be used. the exact length. 20mm. pressure gauge calibration record. Bharat Heavy Electricals Limited Rev 00. This requirement may be waved-off for repeated order if felt necessary. repair replacement free of cost will be done by suppliers. 7-98 . INSIDE THE BOX ALSO. If site trial show higher time of achieving the elongation. SCALE SHOULD BE FLAT & MOVE VERTICALLY UPWARD OR DOWN WARD FREELY. Only after such successful field demonstration device will be finally accepted.STEAM TURBINE 500 MW ERECTION EASY ASSEMBLY & DISSEMBLY. ON THE LID OF THIS BOX FOLLOWING MARKING BE PUT "STUD ELONGATION MEASURING DEVICE". PACKING & DESPATCH COMPLETE MEASURING DEVICE SHALL BE PUT IN A LINEN LINED DURABLE BOX.D & thickness. DESIGN DOCUMENT & PRE APPROVAL DOCUMENT Minimum three copies of assembly drawing with item number. COMPLETE GAS HEATING DEVICE SHALL BE NICELY PACKED IN A WOODEN BOX FOR AVOIDING DAMAGE DURING TRANSPORTATION. Heating tube shall also be punched with the O. Measuring red extension piece. Suppleir has to demonstrate its use & operation at his own cost. DESIGNATION/IDENTIFICATION Each gas heating device should be designated based on the stud heating hole.
Many times after drilling / reaming of holes at works the sizes are taken and pins are dispatched after manufacturing without actual fitting. A special care is must while making the breech nut assembly first time at site during erection stage. These dowel pins causes serious problem during assembly of breech nut at site if the holes are not properly reamed and dowel pins are not fitted at works before dispatch. This type of connection are very useful in barrel type design of HP module and helps in very fast assembly / dismantling of the module in erection and subsequent overhaul of the unit. The faces of the ring may be checked for the line contact on a surface plate. Ensure cleanliness of the inlet insert and HP casing matching flanges. Ensure compression of U seal ring before its assembly. 7-98 . U-seal High temperature molykote is to be used during assembly of breech nut in all the area and matching flanges of inlet insert / HP casing are to be applied with birkosite / stag-B jointly compound.STEAM TURBINE 500 MW ERECTION ASSEMBLY OF BREECH NUT The breech nut assembly used in between connection of main steam inlet line and HP module. Bharat Heavy Electricals Limited Rev 00. Ensure fitting of all radial / axial dowel pins of the breech nut before its final assembly.03 mm feeder tight joints are to be ensured on faces A & B from all the inspection holes of the periphery before heat tightening of the breech nut. A feeler tight joint is to be ensured on these faces during its assembly. The number of breech nut depend upon the numbers of steam entry connection for the HP module. However there are generally two / four breech nut assemblies are used in a particular module. The main steam inlet line connections are welded with the HP casing inlet insert after assembly of the breech nut and no major correction of breech nut is possible unless the inlet line are cut and rewelded. A 0. The value of heat tightening is mentioned over the drawings. PROCEDURE / SPECIAL CHECKS DURING ASSEMBLY OF BREECH NUT AT ERECTION STAGE. Ensure that no burrs / high spots are left on threading portion of the breech nut and all the threads are very smooth.
A similar procedure of heating the breech nut is used for loosing it. After loosing of the breech nut fully the locking of pipelines are to be made free. Bharat Heavy Electricals Limited Rev 00. Proper size pins are to be used on periphery holes of breech nut to avoid any damage of periphery holes are any damage to inside threads of the breech nuts. The welding works of HP casing inlet insert pipelines may be taken up after heat tightening of the breech nut. The radial dowel pins of the breech nut are also to be locked in position to avoid their falling at a later date. 7-98 . DISMANTLING OF BREECH NUT DURING OVERHAULING. The tightening of breech nut is done with the help of overhead crane in both the condition i. during normal tightening and during heat tightening of the nut. Ensure that radial holes of breech nut are covered properly to avoid entry of any foreign material. The tightening of breech nut is done with the help of overhead crane in both the conditions i.e.STEAM TURBINE 500 MW ERECTION The heat tightening device supplied with the machine is to be used for heat tightening of the nut. The proper welding procedure are to be used during locking of the pipelines if these are locked by welding method.e. The offset of pipelines may be recorded at this stage and any major variation in pipeline need correction by cutting / rewelding of pipelines. Though perfect free joint are made during welding of the main steam inlet pipelines with the breech nut but still the problem of piping pull are phased in these area during the various reasons. during normal tightening & during heat tightening of the nut. Hence it is essential to lock the pipeline to avoid its movement in any of the direction. But before the heating / loosing of breech nut the main steam inlet pipe lines need their locking to avoid any type of load transferred on the threads on the breech nut. Proper size pins are to be used on periphery holes of breech nut to avoid any damaged of periphery holes are any damaged to inside thread of breech nut.
7-98 . During checking of the rotor alignment. Similar procedure of assembly of breech nut may be used as explained during erection stages. lifting of HP module etc. If any of the dowel pins are loose then the same can be removed before loosening the nut. This will cut short the overhauling duration of the machine. Bharat Heavy Electricals Limited Rev 00. lifting of LP rotor. To cut short the time cycle of overhauling the rotor alignment and catenary may also be corrected at this stage itself so the further work of overhauling like removing of generator rotor. Ensure fitting of radial dowl pins of the breech nut. U-seal ring are to be ensured for their line contact and compression value before reassembly. may be taken up as per the requirement.STEAM TURBINE 500 MW ERECTION PROCEDURE/SPECIAL CHECKS DURING DISMANTLING/REASSEMBLY OF BREECH NUT IN OVERHAULING OF THE UNIT Ensure locking of the inlet pipeline to avoid any load on the threads of the breech nut due to pull / push of the pipe line an any of the direction while opening it. Any major variation of alignment and parallelity of pipe line are to be corrected before its assembly. the instruction issued against spring loaded foundation are to be followed. During opening and re-assembly of breech nut if any additional load is transferred due to pull / push of pipeline on breech nut threads then that may cause seizure / damage of the breech nut threads. Ensure parallellity of inlet insert and its alignment with the HP casing before its assembly. These dowel pins play a major role during its re-assembly. OVERHAULING OF KWU DESIGN 200 / 250 / 500 MW TURBINE IN CASE OF SPRING LOADED FOUNDATION In case of spring loaded foundation the alignment and catenary of HP / IP / LP /Gen. Ensure that all the radial dowel pins of the breech nut are intact before opening the nut. The pipeline hangers may be adjusted at this stage if required. rotors are to be checked before lifting of any major component from the TG deck .
rotors . The majority of adjustment in achieving the catenary of the shaft may be done by adjusting the shims in the TG deck spring. The adjustment of shims in the bearing spherical / cylindrical seat is limited by + / 0. 7-98 .50 mm in pedestal seal bore values from its base values. casing packers etc. During correction of rotors alignment the catenary of the shaft is also to be maintained. may be taken up individually otherwise most of the above works are to be kept pending for alignment of the HP / IP / LP / Gen.STEAM TURBINE 500 MW ERECTION By following above procedure in overhauling of the unit the various works of individual casing like fitting of radial keys. Bharat Heavy Electricals Limited Rev 00. axial keys.
It shall be necessary to use wooden pattas/probe for compacting the sprayed mass in congested and other locations in order to provide required density and thickness. 6. the lloyd bond binder in the form of a finely distributed concentric spray.0). The MS Rod of 10 mm dia having length equivalent to insulation thickness are welded on the MS frame at a pitch of 250 mm (max. Bharat Heavy Electricals Limited Rev 00. 1. 7-98 . The surface temperature limit 2. 5.on Rockloyd fibers (HT) shall be sprayed using specially designed spraying equipments and accessories. The holding construction shall be separately made for top and bottom half of the casing for ease of maintenance. 4. additional framework of MS strips shall be provided to impart adequate strength to the holding structure. All thermocouples shall be masked with sleeves made out of Aluminium sheet for proper access during maintenance and replacement when and where necessary.STEAM TURBINE 500 MW ERECTION CONSTRUCTIONAL DETAILS AND APPLICATION PROCEDURE: The following constructional/installation procedure shall be adopted. The sprayed lloyd bond binder wraps up the fibers and the wetted strike the surface to be insulated forming a continuous monolithic layer. dirt and such residues. required. The holding construction shall consist of MS strips of 25 x 3 mm which shall be secured either with nuts and bolts or tack welded on the pads already provided on casing surface for the purpose. The turbine/ valve casing surface shall be cleaned with wire brush to remove dust. The required bulk density and the Lloyd Bond binder proportion shall be achieved by controlling the fiber output and lloyd Bond binder quantity. The spray gun provided at the end of the hose. Casing flange joint (parting plate) shall be provided with a separation made out of Aluminium sheet ( 2 mm thick) as a distant line between top and bottom half of the insulation. Any contamination due to oil/grease shall be removed with suitable solvent. Wherever. supplies. The fibers shall be processed to a desired pattern and finally conveyed to the application point by means of a hose. 3. Each layer shall be individually supported with the help of wire netting and MS retainers. Sprayed .
The ends of wire netting at the longitudinal and circumferential joint shall be butted together to ensure that no gap is left at the joints and then laced with GI wire of 0. 7. upto 4 mtr. Length. Length. Individual layer of mattresses shall not exceed 75 mm in thickness and shall be applied ensuring snug fit with the surface. 7. 8/10 mm thick Cat-9 (Bond Seal) finishing cement plaster shall then be trowel applied over the LRB mattresses for piping below the casing. INSULATION APPLICATION FOR PIPING 1. This shall finally be finished with the coat of Lloyd FR paint. The Cat-9 (Bond Seal) finishing cement plaster shall be trowel applied all over the insulated surface with a first coat of 4-5 mm. Bharat Heavy Electricals Limited Rev 00.1 mm. 2. 5. 6. 3. special duty oil resistant and heat resistant coating in thickness of 80 / 100 microns. The final coat of Cat-9 (Bond Seal) shall be applied after reinforcing Lloyd fabric all around the plastered surface. 4. All the joints in insulation shall be properly staggered. shall be finished with Cat-9 hard setting compound upto 4 mtrs. 8. NOTE: All the pipes below turbine casing where spray type of insulation is finished and mattresses insulation starts. Likely Resin Bonded Rockloyd (LRB Mattresses) factory made machine laid machine stitched mattresses conforming to IS : 8183 having GI Wirenetting on one side of design thickness shall then be applied over the pipe surface. dirt or other such residues.STEAM TURBINE 500 MW ERECTION shall be relaxed in restricted locations with the above mentioned constraints. The surface of the piping shall be cleaned with wire brush to remove dust. 7-98 . The surface shall finally be finished with a coat of Lloyd FR pain 80/100 microns of special duty oil resistant and heat resistant coating.
Above shall be insulated with sprayed Rocklloyd Fiber (HT) after thorough cleaning with the same procedure as applicable for cylinder casings. Bharat Heavy Electricals Limited Rev 00. The insulation shall finally be finished with Lloyd FR Paint special duty oil resistant. INSULATION APPLICATION FOR ESV’S IV’S MAIN STEAM VALVE LP BYE PASS VALVE CHESTS.6 above. 3. 8 / 10 mm Cat-9 (Bond Seal). 2.STEAM TURBINE 500 MW ERECTION 8.7 mm Aluminium sheet shall be provided duly rolled and grooved by self tapping screws. heat resistant compound of 80 / 100 microns thickness. 7-98 . 1. For all other pipes 0. finishing cement shall then be provided as explained in 9.
MATERIAL RECD.STEAM TURBINE 500 MW ERECTION NAME OF CONTRACT PAPCKAGE THERMAL INSULATION PACKAGE FIELD QUALITY PLAN FOR TURBINE INSULATION MATERIAL RECEIPT/ STORAGE/PRE-ERECTED/ ERECTION/PRECOMMISSIONING/COMMISSION ING/POLST COMMISSIONING QUANTUM//F REQUENCY OF CHECK 100 REFERENCE DOCUMENTS & ACCEPTANCE STANDARD EQP NO.C. AT SITE TO BE CORELALTED WITH chp/mdcc AND bATCH nO. GI wirenettin g/ GI wire shall be used. Suppliers Literatures enclosed (Annedxure-1) • Oil Resistance compound painting Covering capacity Measuring tape -do- Bharat Heavy Electricals Limited Rev 00. grease etc. REV. These reading. DATE PAGE REMARK S SNO CHARACTERISTICS / ITEMS MATERIAL RECEIPT TYPE OF CHECK INSTRUMENT CLASS FORMAT OF RECORDS Log Book Corelation of Batch No. grease. Log Sheet Thickness Thickness Gauge Minor Visual Physical Minor 100 % • Supporting of retainers • Finishing with Plaster Visual Thickness Physical Thickness Gauge Minor -do- 100 % Three reading on each component to be taken. Is more than 400 Deg. Thickness/ Size/WRT/ CHP/MDC C -do-do-do-do-do-do- 1. 7-98 . Visual -do- -do-do-do-do-do-do- -do-do-do-do-do-do- -do-do-do-do-do-do- • IS-3677 • • IS-6528 • IS-280 • IS-9743 • Berger Make Physical -do- Minor -do- 100 % 100 % check for dirt. SS Wirenetting/ wire shall be used wherever the temp. Approved insulation thickness schedule. BHEL Engg. wetness etc. Approved insulation thickness schedule. (WHICHEVER IS APPLICABLE) -do-do-do-do-do-do- VISUAL Minor • Sprayable granulated Mineralo Wool • Bonding Agent • SS Wirenetting/SS wire • GI Wirenetting/GI Wire • Self Setting cement • Oil Resistance Paint 2. IN PROCESS • Supporting os Structure • Surface Preparation(Physical) • Spray of 1st layer of insulation and subsequent layers(Thickness of Insulation for each layer). at the beginning of application.I. wirenetting/ GI wire after subsequent layers. rust. • Fixing of SS wire netting/ SS wire after first layer and G. in BHEL Engg. Three reading of each component to be taken Shall be free from dirt.
On Components (One per job. Approveod bulk density schedule.5 mtr. Tender Spcen. 3. 80-100 Microse.do Temperature Measurement/ -do- Thickness Micromete r Digital. SPRAYED OF ROCKWOOL Mix.C.C. thickness Thickness gauge Minor Thickness . Of surface. if required later on. double readings must be ensure for any re-tests. Wherever samples are drawn for testing at site. BHEL Engg. FINAL CHECKS • Completion of sprayed rockwool insulation • Hard setting cement • Oil Resistant Compound • Surface temp. Procedure Tender Spen. -do- Minor -doMajor ` -do- Random (Three readings at different pts. IS-3144 & 9742 IS-5724 & 9742 T. 2. • Total Ins. at the end of application. Course of applications.) • hermal conductivity • Heat Resistance • Density • Incombustibility • Compressive strength BHEL APPD.STEAM TURBINE 500 MW ERECTION Mid. Thick ness schedule. lAB. From ccladding surface.) Five readings Five readings after drying Five readings at different pts. BHEL Appt. Three readings at different pts. 7-98 . Appd. contact. -doStandard Template LAB LAB Major -do-do-doMajor Two samples One Samples -do-doOne sample IS-3346 & IS9742 IS-3144 & 9742 BHEL Engg. Pre-Commissioning checks to be finalised with Operational Services. no cracks. -DO- -DOT. Over finished surface • Ambient Temp. -do- -do-do- -do- Visual Minor Note : 1. Of 1. 4. At a dist. Data sheet). Bharat Heavy Electricals Limited Rev 00. • Finished insulation surface. Log sheet.
STEAM TURBINE 500 MW ERECTION Bharat Heavy Electricals Limited Rev 00. 7-98 .
STEAM TURBINE 500 MW ERECTION Bharat Heavy Electricals Limited Rev 00. 7-98 .