STEAM TURBINE

500 MW

ASSEMBLY PROCEDURE OF
IP MODULE AT SITE

ERECTION

ASSEMBLY PROCEDURE OF IP MODULE

Due to oversize dimension of the IP module (M30 - 63) and its limitation in
transportation from Hardwar to site, the same will be dispatched to site in dismantled
condition in various packages after completing the shop assembly at Hardwar. First
the complete assembly of IP module will be done at works except the heat tightening of
parting plane bolts of IP inner and IP outer casing. Afterward complete casing will be
dismantled and dispatched to site.
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 AT SITE :

Place IP outer casing lower half in position after its cleaning over the pedestals
by

supporting it on the Jacking screws at four corners of casing.

Additionally support the casing on temporary packers with the pedestals

also.
Align IP outer casing radially with the help of piano wire keeping the HP rear
and IP front pedestals seal as reference. Install temporary radial keys of
the IP outer casing with the pedestal.
Clean and install IP inner casing lower half along with its radial keys (Drg. No. 0106-01-27500 item No. 25) of front and rear end. During placement

Bharat Heavy Electricals Limited

Rev 00,

7-98

T1-08-0606G
Page No. 1 of 4

STEAM TURBINE
500 MW

ASSEMBLY PROCEDURE OF
IP MODULE AT SITE

ERECTION

of inner casing support it on its four nos. Jacking screws. (Drg no. 0-106-0127500# 18). After placement of inner casing install its axial keys (drg N.
0-106-01-27500 # 20).

Before placement of inner casing install its

thermocouple, parting plane studs (drg N. 0-106-01-27500 # 33 & 34 ).

Seal ring of inlet insert & extraction line (drg N. 0-106-01-27500 #
3,4,9,10,13,14 ).
Place IP inner casing upper half in position and tighten alternate parting plane
bolts. During this process the heat tightening the bolts are not necessary
as this is required for ensuring the feeler tight parting plane joints of the
IP inner casing. The IP inner casing packers are also to be installed
during tightening of the P/P bolts and load of the inner casing is to be
transferred on these casing packers (drg N0-106-01-27500 # 17) fter
taking the load on the packers release the jacking

screws of the IP

casing.
Loosen IP inner casing parting plane bolts and remove IP inner casing upper
half. Before loosening the IP inner casing parting plane bolts support
inner casing again on its four jacking screws and ensure that the parting
plane level of lower half inner casing is not disturbed and remain same
as it was kept after tightening of parting plane bolts with load on its four
packers.
Place IP rotor in position after its cleaning. The front end of the rotor is to be
placed over segment (drg N. 0-106-01-27500 # 21) and rear end of the
rotor on its bearing. During placement of IP rotor ensure that the rotor is
free on its seal fins of IP inner casing and necessary the IP outer casing
may be lowered on its rear end.

Bharat Heavy Electricals Limited

Rev 00,

7-98

T1-08-0606G
Page No. 2 of 4

STEAM TURBINE
500 MW

ASSEMBLY PROCEDURE OF
IP MODULE AT SITE

ERECTION

Provisionally align and couple HP/IP/LP/ Generator rotors and complete

reaming /honing of the coupling including swing check etc.

Before

rotation of IP rotor remove segment (drg N. 0-106-01-27500 # 21).

Set axial position of the IP rotor as per the zero position of the thrust bearing and
set axial position of the IP outer casing as per Hardwar protocol on front
and rear end of the IP outer casing.
Align radially IP outer casing with reference to the IP rotor on front and rear
glands. Recheck/correct axial position of the IP casing.
Assemble IP inner casing upper half end tighten the alternate parting plane bolts
to ensure feeler tight joint.
Do roll check of

IP inner casing by moving the IP outer casing in left/right

direction and IP inner casing itself in up/down direction with the help of
inner casing jacking screws by removing the inner casing packers.
Ensure / compare roll check values with shop records.
Check IP rotor axial float in IP inner casing and compare with shop protocol.
Loosen IP inner casing bolts and remove IP inner casing upper half.
Decouple and lift IP rotor for assembly of rear end shaft seals of IP casing. The
front end of the seals may also be assembled now of afterward with the IP
rotor in position.
Place IP rotor in position and provisionally couple it with HP rotor on temporary
bolts. The IP rotor may not be coupled at its rear end with the LP rotor at
this stage.

Bharat Heavy Electricals Limited

Rev 00,

7-98

T1-08-0606G
Page No. 3 of 4

STEAM TURBINE
500 MW

ASSEMBLY PROCEDURE OF
IP MODULE AT SITE

ERECTION

Assemble and heat tighten IP inner casing upper half as per required elongation
of parting plane bolts. Install seal rings of inlet insert and extraction pipe
on IP inner casing upper half (drg N. 0-106-01-27500 # 1,2,7,8,11,12).
The taper pins of IP inner casing parting planes are to be removed before
placement of IP outer casing upper half after the heat tightening of IP
inner casing bolts.
Assemble IP outer casing upper half and tighten the parting plane bolts to
ensure feeler tight joints. The heat tightening of the bolts are not to be
done now. Before placement of IP outer casing upper half assemble
casing shaft seals of front & rear end also.
Do roll check & float of completely assemble IP turbine and compare it with
factory protocol.
Heat tighten IP outer casing parting plane bolts to required values, and carry out
final roll check and float of completely assembled turbine.

NOTE :

These are general instructions for

the assembly of IP

module M 30 - 63 at site. However, depending on the site conditions the

same may be suitably reviewed, if necessary.

Bharat Heavy Electricals Limited

Rev 00,

7-98

T1-08-0606G
Page No. 4 of 4