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MANUAL
STEAM TURBINE
500 MW
(KWU DESIGN)
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)
New Delhi Executive Director
(PEM & TS)
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.
(BABOO RAM)
NOIDA GENERAL MANAGER(TS&Q)
XX X - XX XX XX X
Alpha Numeric Numeric Numeric Numeric Alpha
Type of
Instruction
System Instruction No
System Designation
Type of Manual
Product Code
B Boiler
BA Boiler Aux.
T Turbine
TA Turbine Aux.
G Generator
GA Generator Aux
P Power Plant Piping
CI C&I
1.2 TYPE OF MANUAL
1 Erection
2 Commissioning
3 Service
01 200/210 MW
02 120 MW
03 110 MW
04 60 MW
05 30 MW
06 100 MW
07 235 MW
08 500 MW KWU Design
09 210 MW KWU Design
10 120 MW KWU Design
11 60 MW KWU Design
12 70 MW KWU Design
13 Industrial Units
14 210 MW Tower Type Concrete Pylem
15 210 MW Tower Type Steel Structure
16 500 MW Tower Type Once through
17 250 MW
18 CCP
SNO DESCRIPTION
1. TECHNICAL DATA
2. INSTRUCTION FOR HANDLING AND STORAGE
OF TURBINE
3. ERECTION SEQUENCE
4. ERECTION PROCEDURE
5. GROUTING PROCEDURE
6. ASSEMBLY OF IP MODULE AT SITE
7. SEALING AND ANTISEIZING COMPOUNDS
8. CRITICAL ACTIVITIES
9. SPRING LOADED FOUNDATION
10. ERECTION OF PIPING
11. SPECIFICATION FOR GAS HEATING DEVICE
12. SPECIFICATION FOR BREECH NUT HEATING
DEVICE
13. SPECIFICATION FOR THERMAL INSULATION
CONSTRUCTION
THREE CYLINDER REHEAT CONDENSING TURBINE 500 MW
EXTRACTION-1 : NO VALVE -
EXTRACTION-6 : NO VALVE
SPEED
RATED SPEED 50.0 /S
STEAM PRESSURES
RATED* LONG TIME SHORT TIME
OPERATION OPERATION
* THESE VALUES CORRESPOND TO 500 MW LOAD WITH 3% MAKE-UP AND 0.1013 BAR BACK
PRESSURE WITH ALL HEATERS IN SERVICE AND RATED STEAM CONDITIONS.
** THE SAFETY VALVES MUST BE SET SO THAT THESE SHORT TIME VALUES ARE NOT EXCEEDED.
LONG TIME OPERATION : UPPER LIMIT VALUE, PERMISSIBLE WITHOUT TIME LIMIT.
AXIAL SHIFT
ALARM TRIP
* 0.5 mm * 1 mm
* DIRECTION OF ROTATION
ANTI CLOCK WISE WHEN VIEWED FROM FRONT PEDESTAL TOWARDS THE
GENERATOR
* THESE VALUES CORRESPOND TO 500 MW LOAD WITH 3% MAKE-UP AND 0.1013 BAR
BACK PRESSURE WITH ALL HEATERS IN SERVICE AND RATED STEAM
CONDITIONS.
** ONLY VALID FOR THE NO LOAD PERIOD WITH HIGH REHEAT PRESSURE AFTER
TRIP-OUT FROM FULL LOAD OPERATION. FOR INDIVIDUAL CASE APPROX. 15
MINUTES
IN THE HOTTEST LINE THE LIMITATIONS INDICATED FOR INITIAL STEAM & REHEAT TEMP. MUST NOT BE EXCEEDED.
O
SPRAY WATER TO LP TURBINE MUST BE SWITCHED ON AT 90 C.
MOTORING :
MOTORING IS THE CONDITION IN WHICH THE TURBINE IS DRIVEN BY THE GENERATOR AT
RATED SPEED WITH THE STOP & CONTROL VALVES CLOSED. IN THIS OPERATING MODE,
CERTAIN TURBINE COMPONENTS ARE HEATED UP BY WINDAGE POWER IN THE BLADING.
TO PREVENT HEAT-UP BEYOND PERMISSIBLE TEMPERATURES, MOTORING MUST NOT BE
ALLOWED TO CONTINUE FOR LONGER THAN ONE MINUTE. IF THE CONDENSER LOW
VACUUM LIMIT OF 0.3 BAR IS EXCEEDED, MOTORING MUST NOT BE ALLOWED TO CONTINUE
FOR MORE THAN 4 SECONDS.
VIBRATION
ABSOLUTE BEARING ABSOLUTE SHAFT
HOUSING VIBRATION VIBRATION
WEIGHTS
HP TURBINE, COMPLETELY ASSEMBLED : 94.6 T
IP TURBINE. TOP HALF OUTER CASING : 25.7 T
IP TURBINE, TOP HALF INNER CASING, COMPLETE WITH BLADING : 15.5 T
LP TURBINE. TOP HALF OUTER CASING COMPLETE : 42.6 T
LP CYLINDER, TOP HALF OUTER SHELL OF INNER CASING, COMPLETE : 38.5 T
WITH BLADING, STATIONARY BLADE CARRIERS & DIFFUSER
QUANTITY 1 2 1 AC : 2 DC : 1
SPEED : 25 S-1
2 EARTH FILTERS
MANUFACTURER : ROTRING
TYPE : PYG5-350
SCOPE
The document covers all steam turbine components and provides the handling,
inspection and storage instructions for large steam turbine components at site.
A strict adherence to these instructions is necessary to avoid damages during
handling and storage at site.
Bharat Heavy Electricals Limited T1-08-0801G
Rev 00, 7-98 Page No. 16
HANDLING OF EQUIPMENT :
In any kind of rigging work it is necessary to strictly observe the safety precautions,
since even the slightest negligence and non observance of the rules may result
in accidents, 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. The loads must not be lifted unless the crane operator can see clearly
the signals given by the rigger.
The positions where the slings are to be put, are marked on the packages and on
the drawings. While lifting/handling these packages/equipment, the slings
should only be put at the proper places.
The slings of the proper sizes and lengths should only be used for handling the
equipment/packages. 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 turbine rotors and cylinder covers (in assembled condition are lifted by the
use of special lifting devices supplied by BHEL. The use of these lifting
devices facilitates correct slinging and maintain horizontal position of the
components. These devices, after use, should be properly stored and
conserved so as to ensure that they do not get damaged during storage.
Before using them, they should be thoroughly inspected.
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. If
the rigger/operator is not sure of the weight of the item/package (load) to
be handled, he must ask for the required information before handling the
equipment.
The rigger and the crane operator should see that the hook and the ropes of the
crane occupy vertical position, before hoisting the load. Dragging of the load
by slanting ropes is not allowed. The center of gravity of the load should be
aligned with the vertical axis of the crane hook.
The eye bolts, 'D' shackles, turn buckles, and wire ropes of suitable sizes should
only be used for handling of the equipment. Before using, they should be
thoroughly inspected to their full threads, so as to avoid any chance of
slipping then the load comes on them.
Before giving a signal to lift the load, the rigger must check and ensure that there are
no loose parts or tools on the load, which might fall during lifting. Then the load
must be lifted 100 or 200 mm high for checking the uniformity of sling
tensioning and reliability of lashing. If it is necessary to rearrange the sling
lengths, the load must be lowered and then the slings rearranged.
Before horizontal conveyance of the load the rigger must see that the load has been
lifted to a height at least 0.5 M above the tallest object, on the path of the load.
INSPECTION
Before storing the equipment it should be opened for visual examination or the
internal packing, protective coating and condition of the equipment. Any
damage to packing and conservation should be immediately rectified.
It is necessary to carryout first inspection within three weeks of arrival of the
consignment. Thereafter, all the equipment should be inspected once in every
three months to insure that the conservation is intact. During rainy season, the
inspection should be done once in a month. At any time, if any original
STORAGE
All steam turbine equipment should be accommodated in the designated place of
storage immediately after arrival at destination. This is very essential particularly
during the rainy season.
TYPE OF CONDITIONS
STORE TEMP. RELATIVE ARRANGEMENT
HOUSE HUMIDITY
PRODUCT : HEATER
1. GLAND STEAM CONDENSER R
2. STAND PIPE Q
3. INSTRUMENTS Q
4. DRAIN COOLER R
5. L.P.HEATERS R
PRODUCT : COOLER
1. OIL COOLER R
2. CONTROL FLUID COOLER R
3. STATOR WATER COOLER R
4. HYDROGEN COOLER Q
5. EXCITER AIR COOLER Q
6. INSTRUMENTS / LOOSE ITEM Q
(For 500 MW Fixed pedestal type Turbine with spring loaded foundation)
1. Cleaning and checking of Turbine and Generator foundations as per the transverse
2. Prepare and install LP base plates, HP front pedestal, HP rear pedestal, LP front
pedestal, LP rear pedestal along with their anchor bolts and anchor plates.
3. Provisionally align and level all the pedestal and LP base plates as per the
4. Matching of anchor plates of pedestal and LP base plates to ensure their perfect
seating.
5. Finally align and level HP front, HP rear, LP front and LP rear pedestals along with
LP base plates as per the transverse and longitudinal axis including their elevation
6. Prepare and install steel bars for LP casing centralising keys in foundation slab as
7. Weld locating ring of LP front pedestal and steel bars of LP front and LP rear
centralising keys.
8. Prepare shuttering and grouting of the pedestals and LP base plates including
9. Prepare, install, align/ level both the LP girder along with their carrier plates.
10. Prepare , install and assemble LP front and rear end walls with the LP girders.
11. Level / align LP outer casing lower half as per the transverse and longitudinal axis
of the machine.
12. Install permanent packers of LP outer casing including their radial and axial keys.
13. Prepare and install LP inner outer casing along with gusset plates in position
platform .
15. Prepare and install LP front and LP rear lower half shaft seals housing and align it
provisionally.
16. Prepare and install LP rotor along with their bellows in position.
17. Align LP rotor radially and axially in position and record free run out of rotor.
18. Record/ Ensure radial and axial clearances of the LP casing including rotor float
19. Box up LP inner inner casing and heat tighten the parting plane bolts.
22. Transfer the load of HP rotor on bearings from the transport device and align it
23. Check free run out of HP rotor on journal and coupling face including its float.
24. Prepare and place IP module in position on temporary packers. (In case IP module
25. Loading of IP rear end of the shaft on bearing and removal of transport device.
27. Couple HP / IP rotor on temporary Bolts and align rotor / casing radially and axially.
29. Conduct Horn drop test of HP casing without any radial and axial keys and pipe
lines.
30. Conduct Horn drop test of IP casing without IP inlet upper half pipe lines.
31. Assembly of breech nut of HP casing and Main Steam Stop & Control valve
assembly.
33. Weld IP inlet upper half pipe and record Horn drop values without radial-axial keys.
34. Alignment of HP/IP/LP rotors and their coupling on temporary bolts including its
couple runout.
35. Swing check of HP rotor on its front end with temporary alternate bolt tightened on
HP/IP coupling .
37. Reaming/honing of HP/IP and LP/IP coupling including fitting of final coupling bolts.
38. Fixing of axial position of shaft and assembly of thrust bearing including its colour
matching.
39. Roll check of HP/IP casing and fixing of radial and axial keys of the casing (Casing
40. Assembly of bearings and checking of all clearances including fittings of side pads
41. Turbovisory works in all the pedestal i.e. assembly and calibration of thrust bearing
axial shift, LP rotor expansions pick up, Hall generator and thermocouples of
bearing .
43. Oil flushing of the machine and normalizing the bearing after oil flushing.
46. Final tightening of HP/IP, IP/LP , LP/Generator and Generator / Exciter coupling
after correcting the alignment including their couple run out and swing check of rotor
pump in operation and water in the hot well of condenser upto operating level.
48. Roll check of HP, 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.
49. Assembly of final packers of the HP, IP casing after completing the roll check in up
50. Recording of final Horn drop of HP and IP casing after completing the welding of
51. Preparation and boxing up of LP casing after competing the full Roll check of LP
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.
Ensure proper locking of all the insert and fixed points before grouting.
Preserve machined surfaces of all the fixed points against any damages due to
Improper handling.
Ensure proper flatness of the bottom seating plate of all the inserts.
Ensure proper stiffeners in all the vertical and horizontal embedment provided
for various purposes like hangers and supports etc.
Close all the pipe sleeve from top to avoid entry of concrete inside. Alternately
the pipe sleeve should be filled with sand.
Ensure there is no loose concrete layer in the region where the pedestal and
base plates are to be laid. No repair should be done in this region without
consulting the turbine erection engineer.
Establish a suitable longitudinal axis considering the fixed point of the LP rear
pedestal and various pipe sleeves / inserts.
Measure elevation of all foundation on different pedestal and LP base plate area.
Check level of LP rear pedestal fixed points and if required correction may
be carried out.
Clean and deburr piping sleeves of the foundation on ID/OD of the pipe.
Ensure all corners of the foundation remains perfect during chipping of extra
concrete of foundation.
Ensure there is no paint on inside surface or the pedestal and if required sand
blasting may be carried out at site.
Ensure that the pedestal parting plane is feeler tight after tightening all the
parting plane bolts. If required, colour matching may be carried out but
scraping/cutting is to be done on upper half cover only.
Ensure cleanliness of all pedestal oil lines. Close opening of oil lines of
pedestal to avoid any foreign material entering in these pipe lines during
erection at site.
Weld MOP suction and discharge pipe lines in HP front pedestal as per the
drawing before placement.
Assemble anchor bolts along with anchor plate of the pedestals. Ensure that
there is good contact available to the backing plate with the
foundation. If required colour matching/grinding may be carried out to
achieve the contact.
Assemble protection sheet in the anchor bolt hole from bottom side of HP rear
pedestal foundation to avoid entry of grout metal.
Ensure level of both anchor plate of H.P. rear pedestal with 70-90 mm gap for
filling of grouting concrete.
Put identification marks on each base plate to avoid any mistake in positioning of
the same.
Do colour matching of all the eight nos. carrier plate on both the faces.
Place all the four base plates in position along with their leveling screws and
foundation bolts.
Align and level LP rear pedestal and set the elevation as per machine center line.
Use piano wire arrangement with micrometer for centering of pedestal bore and
use water level jar for setting of elevation. Use measuring tape to
maintain pitching of the bearing from one pedestal to another. Pedestals
are to be set in level condition on both longitudinal and transverse
direction. Align and level HP front, HP rear and LP front pedestals.
Elevation of the pedestals are to be set as per catenary of the machine
considering the half bore error of the pedestal if any.
Align and level, LP base plates. Elevation of LP base plate is to be kept higher
than the rear pair of LP base plate in line with catenary of rotor.
After alignment of LP rear pedestal weld the locating rings as mentioned in the
drawing.
Seal anchor bolts holes after filling of gravel to avoid any entry of grout metal.
Medical tape may be used for sealing of these anchor bolt holes.
Make shuttering of all the pedestal and LP base plates. Use thick polythene
sheet inside the shuttering to give better finish and avoid moisture
absorption by shuttering.
Shuttering should be made with maximum care to avoid any leakage of grout
concrete. All sides of the shuttering are to be sealed either with some
sealing compound or with thick mixture of grout material to avoid leakage
of grout material.
Non shrinkage cement duly approved by BHEL is to be used for grouting of the
pedestals and base plate.
Use fresh stock of the grouting material only and check the strength of the
material before use.
During grouting, the mixture has to be poured from one end only and it has to
flow to opposite end to avoid any blockage of air pocket.
HP, IP & LP module placement work can be taken up after 24 hours of grouting
of the pedestal and base plates.
For individual pedestal and base plate, grout mixture should be poured in one lot
only.
Ensure matching and parallelity of front and rear key block of the HP casing.
Assemble all four jacking screw of HPC and ensure their free movement.
Record journal dia, coupling hole sizes and spigot dia of HP rotor.
Ensure load on all four packers with the help of some additional shims if
required.
Prepare HP rotor for alignment (Ref. section 20 before placing the IP module.
Ensure matching and parallelity of front and rear key block of IP casing.
Assemble all four jacking screws of IP casing and ensure their free
movement. If these jacking screw holes are provided with the bolts
from factory then same are to be removed before placement of module.
Lift the module in level condition and place the module in position by moving
about 7 to 8 mm towards generator end. Use temporary packers for
placement of module in position and additionally support the module with
jacking screws.
Ensure load on all four packers with the help of some additional shims if
required.
Provisionally align the casing on front and rear pedestal bore. Install temporary
radial and axial keys of the casing with some shims.
ASSEMBLY OF LP MODULE
This assembly can be divided in following sub assemblies:
Two nos. centering pins are to be located below LP front and LP rear pedestal.
Necessary pipe along with two sq. end plates are already provided in the
foundation to take the radial load of the LP casing:
Plumb the center line from LP front and LP rear pedestal bore on both side
over the square plate of the foundation.
Establish accurate position of the pin and put a punch mark at a required height
and mark a circle and a controlling circle over all the four sq. Plates.
Make precise hole with gas cutting/grinding to match template on all four
embedded plate. Ensure that the template is fitted with minimum
clearance and hole center are perfect as per marking.
Drill hole of about 10 mm dia on one of square plate of LP front and on one
plate of LP rear for air venting to avoid cracks during welding.
Insert both the pins and carry out the welding as per laid down procedure.
Before welding set correct axial position of the pins.
Insert key block on both the pins and weld their locking ring also. Ensure
proper clearances in key block before welding of its locking ring.
Colour match seating flange of girder where it rests over the LP base plate.
Place left and right girder with carrier plate, spacer and lubrite packer on LP
base plate.
Provisionally align and level the girders. Set height of the girder equivalent to
machine center line maintaining catenary of the machine with the help of
water level jar arrangement.
Assemble locking plate of the front and rear end wall to facilitate its assembly
with the girders.
Assemble front and rear end wall with the girders and ensure perfect parting
plane level during tightening.
Assemble inner outer casing axial key blocks on left and right side of girder
and dowel them.
Put a seal weld run between girder and end wall joint all around except on top
face.
Weld girder and end wall parting plane joint with argon welding. Before
welding make a V groove with the help of a chisel and allow the projection
of material on surface. Do not make the groove by grinding.
Do colour matching with a surface plate on all four corner where argon welding
have been carried out.
Do colour matching on all four corners of the casing where it rest over the
girder.
Colour match all eight carrier plates of inner casing on both side.
Assemble all carrier plates on girder and 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.
Level and lift LP inner outer casing and assemble/weld both the gusset plates
with the help of some temporary support.
Lower the casing in position over the carrier plates fitted with spacer and lubrite
packer.
Support the gusset plate with the help of screw jack (about 10-15 tons) on front
and rear side by taking support from condenser stiffeners. Screw jack is to
be unscrewed after box-up.
Ensure that all the eight packers have good contact. Loading of each packer is
to be ensured.
Lower the casing by about 2 mm on all the eight packers with the help of shims
for placement of LP rotor to avoid any fauling during placement of rotor.
Fit and weld all gusset plate stiffener pipes except pipe between LP inner outer
casing and condenser. Do not make any weld connection between
condenser and any of these stiffeners till neck welding of the condenser
is over.
PLACEMENT OF LP ROTOR
Measure journal dia, spigot dia and coupling hole sizes.
Lift LP rotor with the supplied lifting beam in perfectly level condition and place
it in position. During lowering of rotor ensure radial clearance with the
help of long feeler gauges in the LP casing.
Ensure good contact between parted diffuser of LP front and LP rear cover.
Colour match and remove all the high spots of the parted diffuser/vertical face
to ensure good contact with the compensator at a later stage.
Colour match and remove all burrs and high spots from parting plane of LP outer
casing.
Side flange of LP front and rear cover are to be ensured in right angle to
achieve good contact with their matching flanges.
Place LP front LP rear cover along with parted diffuser and ensure feeler tight
joint after tightening the parting plane bolts. The joint must be feeler
tight just after normal tightening of bolts. Do not over tighten parting
plane bolts.
Drill/ream all the parting plane holes as per drawings and install all dowel pins.
After fixing of LP front and rear cover measure the dimension for
positioning of both the center flanges. The dimension are to be recorded
in such a way that there is no clearance after fitting of center flanges in
position on both side with the LP front and rear cover. The center
flanges are supplied in extra length on both sides from the factory and
final length are to be maintained at site only.
Drill/ream dowel pin holes in center flanges and install all dowel pins in position.
Ensure drilling and reaming of all dowel pin holes to equal depth.
Achieve the fitting clearances for welding as per laid down procedure.
Weld/lock LP upper half flange with respect to lower half casing with the help
of metal cleats to minimise the distortion during welding of LP cover.
The cleats may be welded at an interval of about one meter distance.
WELDING PROCEDURE
Tack weld the crowned seam joint. permanently welding approx. 100 mm at the
generator end of the joint.
Opposite tack welded radial joint 2, permanently weld approx. 100 mm of the
crowned seam joint, pos. 1, staggering the two weld ends to ensure a
perfect transition when the crowned seam joint is finish welded.
When welding radial joint 2, shell plates 1 & 2, tacked together, rest on but are
not tacked to the retaining strip in the region of joint 1, so that any
shrinkage occurring during welding of seam 2 is not obstructed.
The tacking & welding sequence applies for all shells courses.
Insert pins in top half casing, release top half casing and lift to insert and tack
filler piece between joint strips.
Unbolt top half casing and lift in order to weld and finish - machine filler pieces in
the region of the joint surface.
Fix temporary radial and axial key of the casing on both front and rear side of
the casing. Remove HP front upper half transportation device.
Reduce 0.20 mm shims gradually and ensure about 0.10 mm load on the rotor. If
required further lower the front side of the module to achieve the loading
on bearing by about 0.10 mm.
During loading of bearing always ensure that the rotor is not fouling inside the
casing with the shaft seals. This may be ensured by checking with feeler
gauge also.
Check axial position of HP rotor in front side on left; right and top position
from the rotor reference point to the HPC as given in the shop protocol.
Insert and load the bearing in HP rear end in similar way as carried out in
case of HP front end and record axial position of rotor as per shop
protocol.
Lock axially HP rotor with some fixture along with the arrangement of
jacking screw for movement of rotor. This fixture may be mounted on rear
pedestal. Before locking of rotor ensure axial position of the shaft.
Center HP shaft with reference to HP casing front and rear spigot. If necessary,
move the casing readily to achieve the centering. A fixture can be
fabricated at site for mounting the dial gauge on both the end of the rotor
to check the centering of the shaft.
Realign the rotor shaft with respect to pedestal seal bore and if necessary
adjust the shims below spherical support of the bearing.
Care should be taken during alignment that radial and axial clearances
between rotor and casings does not get bridged.
Check axial run out on thrust collar and both the coupling faces of HP rotor.
Check axial float of the rotor. Compare values with shop protocol values. (Ref. T1-
08-0802G). Deviations to be reported to Manufacturing Unit.
Provisionally align HP/IP rotors and couple on temporary bolts by moving both
the modules. During coupling of the rotors, the transportation device of IP
front end is also to be taken out.
Check axial position of rotor w.r.t. IP casing and adjust as per shop protocol.
Check centering of IP rotor front and rear end w.r.t. IP casing (similar to the HP
rotor centering check).
Check float of the IP rotor. Compare values with the shop protocol values. (Ref.
T1-08-0802G). During checking of float ensure HP casing is not fouling
with HP rotor. If required HP casing may be moved axially for this purpose.
Check facial runout on IP rear coupling face and radial runout on journals and
couplings.
Align LP inner outer casing radially with the help of long feeler gauges and
install temporary radial keys in the gusset plate.
Remove shims from the front end of auxiliary bearing and keep rotor on lifting
tackle.
Record radial run out of LP rotor coupling and journal and axial run out of the
coupling faces of the both end.
Record float of the LP rotor by moving the LP inner outer casing lower half.
After ensuring the radial and axial run out of the LP rotor the LP inner outer
casing can be boxed up. Parting plane bolts of LP inner-inner casing are to
be heat tightened.
Match coupling faces of two rotor as per the axial face reading of the rotor.
Ensure that the higher point of the rotor coupling face and lower point of
another rotor coupling face are matched together. This is to be compared
with shop protocol also.
Preliminary align radially and axially all the three rotors and shift them in spigot
along with the casing to avoid fouling of rotor inside the casing.
During alignment achieve left and right movement of the rotor with the help of
shims in spherical / torus piece of the bearing. The up and down
movement of the rotor is to be achieved with the help of shims in the
cylindrical/spherical support of the bearing . The adjustment of shims in
the bearing should be within the permissible limits only.
Check/record spigot clearance of HP-IP and LP-IP rotors by actually moving them
in spigot.
Install four nos. supplied bolts along with one/two pins in HP-IP and LP-IP
coupling. Hand tighten the coupling bolts by keeping a gap of > 1.00 mm
in coupling faces for alignment.
Rotate the rotor system and record the coupling gap at 90 Deg. interval on
left, right and top position. Ensure that the coupling, bolts and pins
remain free while recording the gap of the coupling for the alignment
purposes.
Ensure free movement of rotor on their bearing. Do not rotate the rotor if it
is tight during its rotation.
Ensue that the coupling holes are properly aligned to avoid unnecessary
enlargement of holes.
Ensure HP-IP-LP rotor radial run out after tightening with alternate clearance
bolts. Release the couplings for reaming / honing of couplings.
First ream/hone two opposite holes of the coupling and install two pins/bolts
with sliding fit and then take up all other holes.
Enlarge coupling holes to the minimum possible diameter and try to make all the
holes to same dia.
Ensure that the finished holes are straight and there is no banana shape. This
can be ensured by checking hole with a straight ground finish pin having
0.02/0.03 mm clearance.
The length of the pin should be equal to the bolt length. In case, few holes have
gone considerably over size during reaming/honing at site/works, do not
enlarge all the holes. As a special case in such cases these few holes
may be left as oversize.
Ensure that the holes during reaming/honing are perfectly finished as ground
bore and size obtained should be within 0.005 mm. Ensure all the coupling
bolts are fitted within 0.02/0.03 mm clearance with sliding fit and bolts are
to be ground within an accuracy of 0.005 mm.
Coupling bolts are not to be hammered in the holes and these are to be fitted with
thumb pressure only.
Do not decouple the coupling in any case without ensuring the fitting of all the
coupling bolts.
If all the coupling bolt hole sizes are same before/after reaming and honing
then all the bolts can be kept of equal weight.
If necessary adjust the weight of the bolts by machining the metal from the bolt
head.
When the holes of the coupling are of different sizes then it must be seen that
whether excess enlargement have been done at site or works. In such
cases if excess cutting have been done at site in a particular hole then
coupling bolt with excess weight are to be used. The amount of excess
weight must be equivalent to the excess enlargement of hole at site. If a
particular hole of excess dia. is noticed from factory then it is assured that
the particular rotor is balanced with excess dia hole and there is no
need of providing excess weight bolt at site.
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.
If necessary move the spherical support of the bearing pedestal to ensure the
equal thickness of the pads before fittment of axial keys of the bearing.
During moving of the spherical support in front or rear direction ensure that
there is no left - right movement to the support otherwise that may
cause misalignment of the bearing.
After colour matching of the thrust pad the axial zero position of the rotor is
achieved and this can be taken for all other future reference for setting of
axial position of HP, IP & LP casing.
HP, IP and LP lower casing are to be set axially after fixing the axial position
of the rotor and their final axial keys can be installed at this stage.
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.
The welding of steam inlet pipes between LP inner casing and LP girders are to
be taken up after completion of roll check of the casing.
HP, IP and LP casing are to be fitted with final packers and axial key immediately
after the roll check. During fitting of casing axial keys and palm packers
ensure proper contact on lubrite coating of the keys/packers to avoid any
damage of these coating during operation of the machine,
After completion of fitting of final keys and packers only the casing are to be
cleared for further works of welding of various pipe lines.
The gland steam, balancing leak of lines, steam inlet and exhaust pipes are to
be welded with HP casing after fitting of final axial keys and packers of the
casing.
Center HP rotor w.r.t. casing front and rear spigots. Compare the readings with
shop protocol and record the readings.
Offset center line of the HP, IP & LP casing w.r.t. respective rotor center line as
per recommended logsheet.
Before roll check of LP casing all the stiffener pipe welding work must be
completed. Refer T1-08-0909G.
Ensure matching of all the parting plane holes, fitting of cap nuts and
accessibility of spanner .
Ensure feeler tightness of the parting plane joint of both the casing.
Ensure proper cleanliness of the LP inner inner and LP inner outer casing.
Ensure adequate clearance between LP inner inner casing and LP inner outer
casing to avoid any obstruction during expansion of the LP inner casing
inside the LP inner outer casing during operation of machines.
All the works must be finished inside the LP casing before boxing up of LP
casing including LP extraction pipe line works.
Ensure matching of all parting plane holes and feeler tightness of the joint
before boxing up of the casing.
Caution:
Preparations for grouting, 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.
PROCEDURE
The foundation should be thoroughly cleaned. 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:- Remove all rust preventive paints, grease etc. 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.
NOTE:- Shuttering must be sealed well to prevent the liquid grouting compound from
running out. This can be done by using paste of grout materials and allowing it sets.
As the grouting compound remains workable for a limited time, to prevent air bubbles, it
must be poured from one side only. For this, a large size filling heaped should be used.
Following measure must be taken before commencing mixing and grouting due to
limited time that the grouting compound remains workable.
Keep the foundation moist for at least 6 hours before the grouting.
-Set up mixers in the immediate vicinity of the foundation plates. The capacity of the
mixers, should be adequate to cope with the quantity of mixed cement required at a
time. Two or more mixers are required for grouting of bearing pedestal foundation
frame.
-Provide the water hose and measuring pans near the mixers.
-Ensure uninterrupted power supply to the mixers and EOT Crane for handling the
ready mix.
-Ensure six empty cubes for filling the grout for strength testing. This is to be done as
per recommended FQP
-Take 80 % of the required water quantity first in the mixture. Then add gradually the
grout, ensuring that no lumps are found. It is desirable to add five or six large sizes
stones to break any lumps. Finally add the balance quantity of water and mix for at-
least another five minutes
Than pour the grout with a hose through the filling hopper until the desired height is
achieved on the opposite side. (Flow may be accelerated by moving the grout in the
filling nozzles underneath the plates with chains or material strips.) This should be done
only if it is permitted by the grout supplier.
CAUTIONS
NOTE:- After at-least 72 hours setting time, work may be commenced on pre-
tensioning of the foundation both.
After the grouting compound has set (approximately. 24 hours after grouting), remove
all shuttering and smooth off the excess grout. The grouting compound is subjected to
The above machines are equipped with the spring loaded foundation deck. As a
general requirement initially all the turbine and generator rotors will be aligned/coupled
without floating the TG deck. 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.
ASSEMBLY PROCEDURE
1. After opening the pedestal remove and clean the bearing including its
spherical/ cylindrical seat.
2. Remove oil guard ring and its duct and keep them in proper place
for their storage at site.
5. Measure bore dia of the bearing and journal dia at site and ensure
the oil clearances. If any discrepancy is observed , designer may be
referred.
9. 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.
10. Torus/spherical should not have any radial movement over its
bearing. This can be seen after opening the torus from the bearing.
11. 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.
12. 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.
14. In case of skew side oil clearances, the investigation may be carried
out, if necessary consult manufacturing unit.
15. 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.
18. 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.
19. 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.
20. 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.
21. 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.
22. 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.
23. 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.
24. The bearing parting plane bolt are to be tightened to required torque
only no other method of tightening of these bolts may be used.
BUMP TEST
The axial clearance check is determined after radial clearance measurement has
been completed.
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.
Note: Enter the measured values ( actual dimensions ) on the record sheet and
compare them with the specified dimensions.
If the deviations from the specified dimensions is greater then the permitted
tolerances, the manufacturer must be consulted.
Note : Based on the readings of bump check, axial position of the shaft wrt
casing is not to be altered.
ROLL CHECK
GENERAL DESCRIPTION
In KWU machine the minimum radial clearances HP, IP and LP casing are measured
by actually by moving the casing radially at site while rotor is rotated by hand. This is
a very accurate and fast method of measuring the minimum radial clearance of any
of the casing.
The major variation in these reading may cause vibration in the machine and
obstruction in barring gear operation etc. Such facilities are not available in many
other designs of machine and causes longer duration in erection and overhauling of
the units.
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 centering of casing may not be fully sacrificed in comparison of rolling test
readings and a compromise between these two readings should be made. The rolling
test should be carried out in cold machine only.
PROCEDURE
ROLL CHECK OF HP AND IP CASING
3. All the four jacking screw of HP and IP casing are to installed along
with dial gauges for monitoring of up and down, and left and right
movement of the casing.
4. 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.
6. 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. During manual rotation two persons are to be
employed for this work and during hand barring only one person is
enough.
7. Always use thick oil for rotation of rotor over bearing in absence of
jacking oil system. The type oil may be servo cylinder 1000 grade
(IOC) oil.
8. During the rolling test the temporary casing packers are to be fitted
with about 1.00 mm shims.
9. During the rolling test of any one of the casing the same is lifted first
on all four corners in a step of 0.05 mm with the help of hydraulic
jack and jacking screw. The rotor is also rotated manually side by
side with the lifting of casing. The rotation of rotor and lifting of
casing continued till it becomes little bit tight on the seals of the
casing
After this the casing is lowered by about 0.05mm 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 0.05 mm on all
four corners. 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.
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. The average lift on front end of the casing is the bottom
clearance on front end of the casing.
After this the casing on front end is lowered by 0.05 mm and
freeness of rotor is ensured. In case it is still tight the casing is
further lowered by 0.05 mm. On front end and the freeness of
rotor is achieved. Now the rear end of the casing are lifted similar
to front end and bottom clearance of rear end are recorded . 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.
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. Before starting the rolling test in
downward direction of the casing remove about 1.00 mm shims
from each packer of the casing, but kept the casing on
hydraulic jacks and jacking screws on its original position. 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 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. During this
process the radial dial on the casing are also installed. After this
check the casing is brought back to its zero position in radial
direction also.
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 casing is then locked on four corners and final dial
readings of spigot are recorded on front and rear end. 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. The final spigot dial reading are repeated and confirmed
with the earlier readings.
10. 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.
11. 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.
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.
13. Radial clearance of the casing are to be ensured with reference to the
factory supplied protocol also.
14. After fitting of final keys and packers of the casing the final spigot
dial values of HP front, HP rear, IP front and IP rear casing are
to be recorded for future reference in the protocol.
15. The horn drop readings are also to be checked after the fitting of
final packer of the casing.
16. In case of IP casing the roll test readings are to be taken with the
IP front end rear shaft scales. The spigot dial readings are also to be
taken over the spigot of shaft seales.
17. 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.
18. Four numbers 1.00 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. If any taper is
left on final packers of the casing then these four packers may be
made to similar taper also.
2. 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.
3. After rolling test of the casing the final radial keys of the Gusset
block and casing packers on all four corners are installed.
6. If the rotor is rotated on jacking oil then the rolling test readings
are to be adjuted for the lift of the rotor also.
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
2. 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.
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.
7. 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.
10. After ensuring the required catenary of the machine the coupling
alignments are to be made as parallel coupling.
Bharat Heavy Electricals Limited T1-08-0804G
Rev 00, 7-98 Page No. 79of 40
STEAM TURBINE
500 MW
CRITICAL ACTIVITIES
ERECTION (CATENARY AND ALIGNMENTS)
11. 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.e. optical measurement method or a method by which
direct journal heights are taken on each bearing in place of pedestal
height.
By horn drop test the loading of the casing on each corner is determined. The horn
drop test is repeated at various stages in individual casing i.e. first without connection
of any pipe lines the horn drop readings are recorded then it is compared after welding
of inlet, outlet and extraction pipe lines etc. The horn drop readings are very important
in HP & IP casing. 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. 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.
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,
obstruction during expansion of machine etc. 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. As such
this gives an indication of indifferent loading of the casing. In Russian design machine
the value of direct dynoxmetre loadings are recorded in place of this horn drop test.
1. Procedure
3. 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.
4. 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. 20 mm on all four corners by
providing shims. This will help in avoiding the touching of seals with
the rotor during the horn drop test readings.
8. 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.
9. 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.
10. All the four Jacking screw and hydraulic jack on each corner of
the casing are to be installed for the horn drop test readings. A dial
indicator is also to be installed on each corner of the casing for
measuring the drop of the casing.
11. After initial centering of the casing the each corner packer may
be fitted with a shim of about 1 mm. for further adjustment during
the horn drop test.
12. 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. Now gradually the jacking screw is also relieved
with the help of hydraulic jack on that corner and drop reading is
recorded. This is repeated for each corner of the casing. 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. 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. 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.
13. 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.
14. During the initial horn drop the best reading within 0.05/0.06 may
be achieved by fine adjustment of the packer shims. The
comparison in horn drop value should always be made in left and
right side only of an individual casing.
15. 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. 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 IP
casing no locking of any corner of the casing is necessary during the
horn drop test.
16. The final packers on HP & Ip casing are installed only after
completing the rolling test of these casing., The horn drop reading
for an individual casing may be recorded after the fixing of final
packers also. If necessary a fine adjustment may be carried out at
this stage to achieve correct value of the horn drop reading.
17. After completing the welding of all pipe lines with the casing , the
horn drop readings are repeated again for comparison with the
earlier readings. These readings are taken along with its radial and
axial keys of the casing.
18. During this stage exactly this can not be defined that how much
variation is permitted on these values of horn drop readings., 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. 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.
20. The variation in horn drop reading of left and right side of a casing
may be permitted upto a difference of 50%.
21. The horn drop readings are not taken for L.P. 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.
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. This is measured on opposite
end of the coupling and at the free end of the rotor. The higher swing check value
may cause higher shaft vibration, higher bearing shell temperature etc. The value of
swing check depends on axial runout of coupling faces, the diameter of the coupling
and the length of the rotor. 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. 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. However it is recommended to keep the
minimum swing check values for better results during operation of the machine.
PROCEDURE
8. While recording swing check of HP rotor the front end of the rotor is
to be supported on lifting tackle.
9. During swing check the lifting tackle are to be fitted properly. 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. These spherical bearing should
not obstruct the movement of shaft radially during checking of its
swing check value.
10. After taking the load of the rotor on lifting tackle ensure that the
rotor is not disturb radially due to fitting of lifting tackle.
barring or with the help of E.O.T crane with thick oil on bearings.
Avoid jerk during rotation of rotor while recording the swing check
values.
12. After ensuring the swing check values as per the graph with on
temporary coupling bolts, the HP-IP and LP-IP coupling may be
cleared for reaming / honing of the coupling holes. Any variation
need correction of the coupling before reaming/honing of the holes.
13. 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.
Any variation in readings may be referred to the Designer's. For
improvement of the swing check values, the indifferent tightening
and non-sequential
14. 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.
16. While recording the swing check initially with temporary bolts for
HP & IP rotor, the fitting of eight number temporary bolts are
preferred in place of four bolts on the coupling.
The coupling on turbine shaft are generally rigid coupling but in case of L.P. rotor
sometime the coupling head are shrunk fit and remachined. The basic function of any
coupling is to connect two or more shaft together to form a shaft assembly. The number
of shaft mainly depend upon the rating of the machine.
A very high accuracy is required during manufacturing of these rotor shaft at
works. The axial runout on the coupling face may not exceed 0.02 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 0.02 mm. except the concavity on
the coupling face which is permitted upto 0.03/0.04 mm.
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. for a particular
machine. The coupling checks determines both the radial and axial position of the
two adjacent coupling flanges relative to one another. The radial measurement are
performed on the circumference of the couplings and the axial measurement are
performed on outer most diameter of the coupling. 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.
After completion of the alignment and coupling of the shaft the casings are aligned
radially and axially. 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.
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.
PROCEDURE
3. Check spigot and recess of the coupling and ensure their fitting
before placement in position.
each shaft. During checking of radial and axial runout of the shaft
place H.P. rotor on both of its bearing and IP/LP rotor one end
on its bearing and another end on the lifting tackle. The radial and
axial face runout on the shaft should be within 0.02 mm accuracy.
Any variation may not be permitted here and matter may be
referred to the designer's.
5. The HP,IP & LP rotor are aligned together and then their couplings
are made. After fully completion of HP/IP & IP/LP coupling with
tightening of their final bolts the complete shaft is cleared for
Generator rotor alignment.
6. 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. After completion of the
radial alignment the rotor are inserted in their spigot even with some
minor variation in their axial gap values.
7. 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. The radial alignment reading along
with axial gaps are necessary wherever the effective spigot are not
existing in two couplings i.e. in case of LP - Gen coupling the radial
dial reading are also taken.
10. 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. But during overhauling of the
machine the adjustment may be carried out in these packers for
correction of catenary of the machine.
11. During alignment of rotor make HP/IP and IP/LP coupling gap
parallel. After completion of final alignment no adjustment of
packers and keys etc are permitted on pedestals and bearing the
12. After alignment couple the HP-IP & IP-LP rotors on temporary
bolts. Record coupled runout of the rotor and ensure that the
coupled runout is not more then 0.03 mm. in any where in the
journal as well as in coupling area. Before coupling of rotor on
temporary bolts record their spigot clearances by actually moving
the rotor radially.
13. During erection IP-LP swing check on IP front and HP-IP swing
check on HP front are to be recorded on temporary bolts. These
reading are to be ensured within the design limit.
15. The HP-IP & IP-IP coupling may be cleared for reaming/honing
after ensuring the runout and swing check values of the rotors. In
case of variation the cause of the error may be identified and
corrected before further work of reaming and honing of the
coupling.
16. 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.
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.
18. All the coupling bolts are to be machined and ground by 0.02/0.03
mm undersize then the hole dia. These bolts are to be fitted with
thumb pressure only and no additional force is recommended while
fitting these bolts.
19. A very thin layer of molykote may be applied on all the coupling
bolts during their fitting. The molykote should not be applied on
21. During tightening of coupling at any stage first tighten four bolts on
90o location. Always tighten bolts in proper sequence with
180o opposite bolts. These bolts are to be elongated to the value
given over drgs.
23. After final tightening of LP-IP and HP-IP coupling the swing check
value on HP front rotor is to be rechecked. In case of variation in
value a proper correction is to be made with consultation of
designer's. The indifferent or unsequential tightening for achieving
the swing check value or coupled runout value may be fully avoided.
this may cause unnecessary stresses on the coupling.
24. After completing the coupling work the casing radial and axial
alignment may be done.
PROCEDURE
The following points are to be taken care while welding MS, CRH, HRH pipelines
with HP & IP casing and control valves / strainers.
5. 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. 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. The freeness of
joints are to be ensured after giving the equivalent insulation weight
of the lines.
6. Weld MS & HRH lines with the strainers and again ensure the
freeness / paralalllity of MS & HRH lines with the ESV and IV
control valves. Any minor variation may be readjusted on hangers to
obtain the freeness of the joints with the control valve.
7. Install the MS and HRH lines between control valves and HP /IP
casing . Now all the in between joints may be keeping the end joints
free with the valve and the casing. 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. The
equivalent insulation weights are also to be added during erection of
these pipe lines before welding the end joints.
8. After ensuring the freeness and parallelity of the end joints between
ESV control valve and HP casing , the same may be welded together.
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 .
Similar proceedure may be followed for the lines between I V valves
and IP casing also.
9. 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 . during
welding the left and right movements of casing may be monitored by
installing the radial dial gauge on the casing.
10. 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. The left and right side casing joints are to be welded
together , similar to MS lines but before weling of these line the in-
between joints are to be completed first . The equvalent insulation
weight is also to be given on these line while checking the freeness of
end joints with the HP casing.
11. 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.
SPECIAL CARE
2. The control valves hanger readings are to be measured with the inside
micrometer in various stages and changes are to be monitored
properly . 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.
− After readjustements of control valve height equivalent to
insulation weight.
− After connection of MS &HRH lines with the strainers .
− After connection of MS & HRH lines with the HP & IP casing .
− After complete insulation of control valve and pipings.
4. 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 .
5. 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.
6. 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.
This may be taken care while erecting the HRH lines.
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 , 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:
The same column of TG deck may also be used to support surrounding floors at the
building , so that the total number of columns are reduced and the space to
accommodate more equipment is increased. This results in more rigidity of building
structure of surrounding floors and further in cost saving.
The shuttering of RCC slab of TG deck is furnished before installation of these spring
units. The top surface of individual column where these spring units are mounted
should be within accuracy of +00 mm to -3.00 mm. If necessary these may be
corrected by chipping before installations of the spring units. The level deviation among
various columns is permitted +00 mm to -5.00 mm in total including individual column
variation of +00 mm to -3.00 mm.
The bottom shuttering of pedestal must be cut over the column head for lowering the
spring units. After lowering the spring unit the cover steel plates are placed in position
with shuttering supports. An air gap of about 5.00 mm to 10.00 mm is left between
cover plate and spring units for settlement of deck during casting. The visco dampers
are also filled up at site only with visco liquids supplied by spring supplier. The filling
procedure of visco liquid is explained separately by the spring supplier.
Each spring units are placed over the resistance pad to avoid movement of the spring
units during operation of the machine. Similarly the resistance pad is given on top of
the steel shim to avoid the shifting of the shim during operation of the machine. Each
spring unit is provided with 10.00 mm of steel shim for future adjustment.
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. If major variation in calculation of load
over the spring units are not expected then an additional compression of 5.00 mm is
sufficient for this purpose. During installation of spring units, additional shims are
provided for this 5.00 mm additional compression and which are removed at the time of
loosening of the spring elements before final alignment of the machine. These
additional shim are removed in minimum two stages after ensuring, 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. It is also
not necessary to remove this complete 5.00 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. Refer section “Releasing
of TG Deck Spring” for removal of additional shims.
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. 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. The coupling bolts need not be elongated at this stage and once all
other works are ready for final alignment of rotors ,the coupling may be opened and
realigned. After realignment , the coupling bolts are to be fitted without any further
reaming / honing of the coupling holes. The radial alignment of HP, IP and LP casing
i.e. rolling test of all these casing are also to be carried out after final alignment of rotor
and with the CWP in operation etc. i.e. with similar conditions of final alignment of
rotors.
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. Similarly the condenser spring measurement should be with in + 1.00 mm
otherwise the shims may be adjusted in condenser springs. No adjustment of TG deck
springs or condenser springs are permitted after final alignment of the rotors. During
any subsequent adjustment of TG deck spring the final alignment of all rotors are to be
checked.
After placement of TG deck springs in locked condition with shims and resistance pad
etc, an equal air gap between 5 .00 to 10.00 mm is left between all the springs and
bottom of the steel cover plate. 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 only. The form work and support of TG deck are removed once the concrete has
hardened sufficiently. This is generally done after 28 days of casting of the deck and
all load of deck is transferred over the spring units . Afterwards TG pedestals are
placed /aligned and their elevation are maintained as per required catenary of the
machine before grouting the pedestals with the non-shrinking cements . During
releasing of TG deck spring while this additional 5.00 mm shims (for additional
compression) are removed the catenary of the machine is to be achieved within + 0.20
mm bearing No. 1&4 with the help of TG deck springs by adjusting the shims and
afterwards only the rotors alignments should be taken up. 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.
The height of TG deck spring are taken on four corners near the springs. Here some
punch mark may be provided on all springs so that measurements are taken at the
same place always. Certain minor variations on height of the spring units are permitted
, if it is required for achieving the Catenary of the machine. 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. Similar methods
are used for release of the spring locking bolts also. These hydraulic jacks are group
operated type and works with one pumping unit which is electrically operated. The
ready-made galvanized shims are also supplied in required sizes alongwith spring unit
in 3.00 mm and 2.00 mm thickness so an adjustment of upto 1.00 mm is possible in
spring Units.
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 sizes of the shims are also recorded for each
spring. A bench mark may also be preserved on TG floor as reference for LP rear
pedestal parting plane height for all future reference. 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 . 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. 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.
Before neck welding all the major components of the condenser are to be installed
including its tubing , water boxes, dome wall assembly and its stiffener pipe, etc. After
installation of all the major components of the condenser the spring are released i.e.
condenser is floated for welding with the Turbine.
After floating the condenser, 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 3.00 mm
depending upon the designer requirements. 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. 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. Sometime during floating of condenser an
additional weight of water is filled up in condenser depending upon the designer’s
requirement.
The TG deck springs are kept in locked condition during the neck welding of the
condenser. 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 +/- 1.00 mm than
the necessary adjustment is to be carried out. 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.
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.
During subsequent overhaul of the unit the condenser spring height alongwith TG deck
spring height need a monitoring. As a general practice whenever the TG deck spring
height are checked then the condenser springs height are also to be checked.
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. All the
connected pipe lines of the condenser are to be ensured on permanent hangers before
floating of the condenser. The condenser neck welding is carried out as per the back-
step method for which the procedure is laid down in KWU manual of steam Turbine
assembly sheet No 1-2-6330-0001/1.
During neck welding the complete height of L.P. inner and L.P. outer casing is installed
in position.
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.
4. Care should be taken to ensure that the deformation is well within the
tolerance limits.
ACCOMMODATION OF MOVEMENT AND EXPANSION.
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.
3. Determine with the aid of the diagram (Fig. 1 & 2 ) the pipe legs
required to accommodate terminal movement and thermal expansion.
4. Ensure the valid coordinate system of that power plant (Fig 13) is
adhered.
3. When fabricated pipe supports and guides, only flat steel pipe clamps
and aluminum clamps serve as the pipe bearing surface.
3. Complete N.D.T.
5. Once the line has been welded to the bearing pedestal, fit a protection
plate to protect the line in this area.
7. Ensure that oil vapor extraction lines are laid with a gradient
descending constancy towards the main oil tank without low points.
A drain loop at the lower end of this line upstream from the blowers
return drains to the oil tank.
8. Fire Prevention
9. To avoid fire hazards, do not route oil lines near lines or components
at high temperature.
10. If the laying of oil lines in these areas cannot be avoided, ensure that
no detachable connections or valves are erected directly above high-
temperature lines or components.
Control Fluid System
Single Fluid Lines
11. 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, almost all fluid lines which do not lead directly from pump
via filter to component). These includes : primary oil lines,
secondary auxiliary secondary and bypass signal fluidlines, trip,
auxiliary trip, test and return fluid lines, by[pass startup fluid
lines, and water filled (condensate-filled) impulse lines.
12. They do not include : turbine start-up and auxiliary start-up oil
lines, pilot fluid line (between pressure transducer and pilot valve
on Nb200 and Nb250 bypass stop valves with LP hydraulic
system).
13. To ensure correct functioning of signal fluid lines, lay them with
an adequate ascending or descending gradient to prevent air
pockets from forming and accumulating. A number of different
routing strategies are available for this purpose (the control
medium flows from the control equipment) Fig. 7.
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. 7.
Version 2.
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. 7.
If it is not possible to install the line as shown in Version 1&2, two other
strategies may be adopted (Fig.8)
Version 3.
If local conditions make it necessary to install the line with one or more
high points, each high point must be provided with permanent venting
facilities (orifices with a diameter of 1.5mm). Fig.8.
Version 4.
If local conditions make it impossible to observe the 10OC minimum
gradient in installing a line as shown in Version-2, then reduce the
1. Insert leak-off and seal steam lines, though the pipe penetrations in
the LP end walls before mounting the LP bearing pedestals. Connect
the lines up when the LP steam seal casings have been fully
assembled.
Pressure Sensing Line Terminals for the Seal Steam Control system
2. Lay the header, with an ascending gradient from the terminal point to
the pressure transducers, making sure that the pipe leg below the
transducers has a gradient of 30OC.
3. From this pipe leg, in which two Nb 25 nozzles are welded, erect two
lines 500 mm long, to the pressure gauge cutoff valves of the pressure
transducers.
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. Fig.12.
DRAIN SYSTEM
Drain Lines
1. All drain lines shall have as steep a gradient as possible, an all cases at
least 20 mm/m.
3. The above lines must have an adequate gradient - at least 1:15 (67 mm/m) -
between their connection point and the transducer rack.
4. Lay pressure sensing lines such that the primary cutoff valve forms an anchor
point, 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. A compensating leg extending 1 meter in
each of two planes should be provided in the lubricating oil, control fluid and
drains system on account of the minimal terminal movement there. (Refer Fig.
10 & 11).
Locking Devices for Threaded Connections.
5. All Fasteners should be locked using tab washers or a suitable thread lock
adhesive.
APPLICATION
This device is used during heat-tightening of cylinderjoint bolts/studs of
steam turbine to a predeterminedjoint pressure. Heating process is
carried out by sending hot oxy-acetylene gases mixed with compressed
air into the holes provided in the bolts stud. 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.
SCOPE OF WORK
This specification covers the broad guide lines on design, manufacture and
supply of gas heating device for the above mentioned purpose. Scope of
supply also covers associated compressed air piping including a fine
regulating valve, pressure gauge & pipe fittings. Source for compressed
air shall be made available. Similarly oxy-acetylene cylinder with heating
torch not covered under this scope.
FUNCTIONAL DESIGN
A typical outline sketches fig. No. 1 showing general arrangement of gas heating
device and fig No. 2 - measuring device are enclosed for reference purpose.
THIS HEATING DEVICE IS A PORTABLE UNIT. HEATING SHOULD BE POSSIBLE
IN ANY OF THE STUD IN ASSEMBLED CONDITION. HEATING SOURCE IS
OXY-ACETYLENE GAS.
OXY-ACETYLENE TORCH IS IGNITED OUTSIDE AND THEN IT IS INSERTED IN
THE HOLE MEANT FOR IT IN THE INLET CHAMBER. STANDARD TORCH
SIZES SHOULD BE SELECTED FROM THE INDIAN OXYGEN LTD;
CATALOGUE, SUITABLE CHAMPING DEVICE FOR HOLDING THE OXY-
ACETYLENE TORCH DURING HEATING PROCESS SHOULD BE
PROVIDED.
MATERIAL OF CONSTRUCTION
While selecting the material for different components of heating device due
considerations to its operation at elevated temperature, high temperature
gradient and thermal cycling to be taken into account.
It is customary to use allow steel (CR-Mo-V or CR-Mo) to provide long life to these
component.
Measuring rod, depth gauge & sleeve material should be hardened and tempered.
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. DEVICE SHOULD BE
EASY TO INSTALL ASSEMBLE AND DISSEMBLE.
DIMENSIONAL ACCURACY, FITTING AND SURFACE FINISH SHOULD BE AS PER
I.S. 2102-1962 MEDIUM, I.S. 2709-64, I.S 3073-67 RESPECTIVELY.
WELDING IF USED ANYWHERE IN ASSEMGLY SHALL BE CHECKED FOR CRACK
& DEFECTS. DEFECTS TO BE RECTIFIED.
DUE PRECAUTION TOWARD OPERATIONAL SAFETY MUST BE TAKEN.
Measuring Unit
8. Measuring sleeve should have both faces parallel and flat. Length
of sleeve should be chosen such that the difference dimension A & C
is more than 150 m.m. (see if fig. 2). Sleeve length C should be more
than dimension LR.
Compressed air system:
1. The hole in the inlet chamber for insertion of heating torch should
match with the standard torch shapes of Indian Oxygen Ltd;
without leaving a large clearance or causing insertion problem.
DESIGNATION/IDENTIFICATION
Each gas heating device should be designated based on the stud heating hole,
20mm, 25mm or 32mm. On the inlet chamber the torch sizes (As per Indian
Oxygen Ltd; catalogue) to be used, shall be punched. Outer tube shall also be
marked for the heating hole size. Heating tube shall also be punched with the
O.D & thickness.
Measuring red extension piece, measuring sleeve shall bear on it, the exact length.
The breech nut assembly used in between connection of main steam inlet line
and HP module. 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 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.
A special care is must while making the breech nut assembly first time at site
during erection stage. 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.
Ensure cleanliness of the inlet insert and HP casing matching flanges. A feeler
tight joint is to be ensured on these faces during its assembly.
Ensure that no burrs / high spots are left on threading portion of the breech nut
and all the threads are very smooth.
Ensure fitting of all radial / axial dowel pins of the breech nut before its final
assembly. 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. Many times after drilling / reaming of
holes at works the sizes are taken and pins are dispatched after
manufacturing without actual fitting.
Ensure compression of U seal ring before its assembly. The faces of the U-seal
ring may be checked for the line contact on a surface plate.
A 0.03 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.
The value of heat tightening is mentioned over the drawings.
The heat tightening device supplied with the machine is to be used for heat
tightening of the nut. The radial dowel pins of the breech nut are also to be
locked in position to avoid their falling at a later date.
The welding works of HP casing inlet insert pipelines may be taken up after heat
tightening of the breech 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
condition i.e. during normal tightening and during heat tightening of the
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.
The tightening of breech nut is done with the help of overhead crane in both the
conditions i.e. during normal tightening & during heat tightening of the nut.
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.
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.
Ensure that all the radial dowel pins of the breech nut are intact before opening
the nut. If any of the dowel pins are loose then the same can be removed
before loosening the nut.
U-seal ring are to be ensured for their line contact and compression value before
reassembly.
Ensure fitting of radial dowl pins of the breech nut. These dowel pins play a
major role during its re-assembly.
Ensure parallellity of inlet insert and its alignment with the HP casing before its
assembly. The pipeline hangers may be adjusted at this stage if required.
Any major variation of alignment and parallelity of pipe line are to be corrected
before its assembly.
1. The turbine/ valve casing surface shall be cleaned with wire brush to
remove dust, dirt and such residues. Any contamination due to
oil/grease shall be removed with suitable solvent.
7. 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. The final
coat of Cat-9 (Bond Seal) shall be applied after reinforcing Lloyd
fabric all around the plastered surface.
1. The surface of the piping shall be cleaned with wire brush to remove
dust, dirt or other such residues.
6. 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, upto 4 mtr. Length.
7. This shall finally be finished with the coat of Lloyd FR paint, special
duty oil resistant and heat resistant coating in thickness of 80 / 100
microns.
8. For all other pipes 0.7 mm Aluminium sheet shall be provided duly
rolled and grooved by self tapping screws.
INSULATION APPLICATION FOR ESV’S IV’S MAIN STEAM VALVE LP BYE PASS
VALVE CHESTS.
NAME OF THERMAL FIELD QUALITY PLAN FOR MATERIAL RECEIPT/ EQP NO.
CONTRACT INSULATION TURBINE INSULATION STORAGE/PRE-ERECTED/ REV.
PAPCKAGE PACKAGE ERECTION/PRE- DATE
COMMISSIONING/COMMISSION PAGE
ING/POLST COMMISSIONING
SNO CHARACTERISTICS / TYPE OF CHECK INSTRUMENT CLASS QUANTUM//F REFERENCE FORMAT REMARK
S
ITEMS REQUENCY DOCUMENTS & OF
OF CHECK ACCEPTANCE RECORDS
STANDARD
1. MATERIAL RECEIPT MATERIAL RECD. AT VISUAL Minor 100 Log Book
SITE TO BE Corelation
CORELALTED WITH of Batch
chp/mdcc AND bATCH No.
nO. (WHICHEVER IS Thickness/
APPLICABLE) Size/WRT/
CHP/MDC
C
• Sprayable granulated -do- -do- -do- -do- • IS-3677 -do-
Mineralo Wool
• Bonding Agent -do- -do- -do- -do- • - -do-
• SS Wirenetting/SS -do- -do- -do- -do- • IS-6528 -do-
wire
• GI Wirenetting/GI -do- -do- -do- -do- • IS-280 -do-
Wire
• Self Setting cement -do- -do- -do- -do- • IS-9743 -do-
• Oil Resistance Paint -do- -do- -do- -do- • Berger Make -do-
2. IN PROCESS
• Supporting os Visual Physical Minor 100 %
Structure
• Surface -do- -do- -do- 100 % check Shall be free Log Sheet
Preparation(Physical) for dirt, grease from dirt, grease,
etc. rust, wetness
etc.
• Spray of 1st layer of Thickness Thickness Minor Three reading BHEL Engg.
insulation and Gauge of each Approved
subsequent component to insulation
layers(Thickness of be taken thickness
Insulation for each schedule.
layer).
• Fixing of SS wire Visual Physical Minor 100 % SS Wirenetting/
netting/ SS wire after wire shall be
first layer and G.I. used wherever
wirenetting/ GI wire the temp. Is
after subsequent more than 400
layers. Deg.C. GI
wirenettin g/ GI
wire shall be
used.
• Supporting of Visual Physical Minor 100 %
retainers
• Finishing with Plaster Thickness Thickness -do- Three reading BHEL Engg.
Gauge on each Approved
component to insulation
be taken. thickness
schedule.
• Oil Resistance Covering capacity Measuring -do- These Suppliers
compound painting tape reading, at the Literatures
beginning of enclosed
application, in (Annedxure-1)
Mid. Course of
applications,
at the end of
application.
3. SPRAYED OF
ROCKWOOL
Mix. On Components • hermal conductivity BHEL Major Two samples IS-3346 & IS- T.C.
(One per job.) APPD. 9742
lAB.
• Heat Resistance -do- -do- One Samples IS-3144 & 9742 -DO-
• Density Standard -do- -do- BHEL Engg.
Template Approveod bulk
density schedule.
• Incombustibility LAB -do- -do- IS-3144 & 9742 -DO-
• Compressive LAB Major One sample IS-5724 & 9742 T.C.
strength
4. FINAL CHECKS
• Completion of Total Ins. thickness Thickness Minor Random BHEL Engg. Log sheet.
sprayed rockwool gauge (Three Appd. Thick ness
insulation readings at schedule.
different pts.
Of surface.)
• Hard setting cement Thickness Thickness Minor Five readings
• Oil Resistant - do - Micromete -do- Five readings Tender Spcen. -do-
Compound r after drying 80-100 Microse.
• Surface temp. Over Temperature Digital, Major Five readings BHEL Appt. -do-
finished surface Measurement/ contact. ` at different Procedure
pts. Tender Spen.
Data sheet).
• Ambient Temp. At a -do- -do- -do- Three -do- -do-
dist. Of 1.5 mtr. From readings at
ccladding surface. different pts.
• Finished insulation Visual Minor no cracks.
surface.
•
Note : 1. Wherever samples are drawn for testing at site, double readings must be ensure for
any re-tests, if required later on.