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500 MW
ERECTION PROCEDURE
ERECTION
of concrete while
T1-08-0404G
Page No. 1 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
About 15-20 mm extra concrete may be left on top on all the pedestals and
LP base plate area for chipping/cleaning purpose at a later date.
Close all the pipe sleeve from top to avoid entry of concrete inside. Alternately
the pipe sleeve should be filled with sand.
T1-08-0404G
Page No. 2 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
A reference point for elevation in respect of machine center line (equivalent to LP
rear pedestal) is to be maintained at a proper place. This point is to be
preserved with proper protection. For making reference point a one side
ground plate of about 200 x300 x20 mm may be used. This may be
welded on a I-beam near Generator. The ground position of the plate is
to be kept on top side and all elevation are to be transferred from this
point with the help of water level jar. A correct elevation reading is
to be punched on this plate. This reference point is to be used only during
the turbine erection period.
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.
PLACEMENT OF PEDESTALS
Open and clean the pedestal.
Ensure there is no paint/oil on bottom face of the pedestal sole plate.
Ensure there is no paint on inside surface or the pedestal and if required sand
blasting may be carried out at site.
Ensure correct fitting/clearance of locating rings of LP rear pedestal.
The half bore error of pedestals is punched by manufacturing unit however in
case it is not there, measure and punch half bore error of pedestal in
left/right
side of the pedestal. If the error is nil then this may be
punched as zero-zero.
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.
Check proper colour contact of spherical/cylindrical supports of the bearing
with the pedestal.
T1-08-0404G
Page No. 3 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Check
contact
between
spherical Torus piece
of
bearing
and
spherical/cylindrical seat. In case of any variation in contact no
scraping/cutting to be carried out at site and this may be referred to
manufacturing unit. Also refer T1-08-0808G. Check centering of individual
bearing w.r.t. pedestal seal bores by fixing pianowire on individual
pedestal.
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 protection sheet in the foundation bolt holes of pedestals.
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.
Adjust height of the Anchor Bolts as specified in the drawing.
T1-08-0404G
Page No. 4 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Place all the four base plates in position along with their leveling screws and
foundation bolts.
Provisionally align and level all the four base plates.
Assemble protection sheet in the foundation bolt holes.
T1-08-0404G
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STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
T1-08-0404G
Page No. 6 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Ensure matching of all the four palms of the module where it is resting on the
pedestals.
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.
Clean journals and coupling of the HP rotor.
Record journal dia, coupling hole sizes and spigot dia of HP rotor.
Lift module in level condition and place it in position by keeping it 3 to 5 mm
toward front pedestal side.
During placement of module use temporary packers similar to permanent and
additionally support it by four jacking screws.
Ensure load on all four packers with the help of some additional shims if
required.
Install temporary radial and axial keys of the casing.
Prepare HP rotor for alignment (Ref. section 20 before placing the IP module.
T1-08-0404G
Page No. 7 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
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.
temporary radial and axial keys of the casing with some shims.
Install
ASSEMBLY OF LP MODULE
This assembly can be divided in following sub assemblies:
Assembly of girder and end walls.
Assembly of LP inner inner and LP inner outer casing lower half.
Assembly / welding of LP outer casing.
Before starting assembly of LP casing in position, following works are
also to be completed :
- Positioning and welding of LP casing centering pin of front and rear
side.
- Positioning of key block of LP casing axial keys.
- Positioning of all internal of condenser.
T1-08-0404G
Page No. 8 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
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.
Dia of the circle must be equal to pin dia. A template equivalent to pin dia
has to be made for this purpose with about 20 mm thick plate and a
welded pipe for using as an handle. The template dia must be very
accurate and same may be made on machine.
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.
Preheating of 200 degree Celsius or more to be achieved before any
welding. Dye penetrate test on root run and after final welding is to be
carried out.
T1-08-0404G
Page No. 9 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
packers by colour
T1-08-0404G
Page No. 10 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
do
the
Prepare Gusset plate of front and rear side with temporary radial keys
fitting in LP inner casing.
for
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.
Provisionally align the casing radially and axially.
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.
T1-08-0404G
Page No. 11 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Adjust the height of the LP inner outer casing as per center line of the machine
and then level it with the help of water level jar arrangement.
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.
Ensure centering of temporary bearing support in the LP front pedestal for
placement of LP rotor.
Place LP rear bearing in position.
Prepare shaft seal compensator along with gaskets (Gasket to be installed in
fully ring shape only ) and position them on LP rotor with the help of
supplied supports of compensator.
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.
T1-08-0404G
Page No. 12 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Colour match and remove all high spots of the matching flange of the LP
outer casing.
Ensure good contact between parted diffuser of LP front and LP rear cover.
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.
Ensure matching of parted diffuser face on both side of LP casing. If necessary
colour matching may be carried out to achieve a feeler tight joint.
Drill/ream all the parting plane holes as per drawings and install all dowel pins.
After
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.
Fit both the center pieces of the cover in position.
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.
Carry out the welding as per the following welding procedure.
Bharat Heavy Electricals Limited
Rev 00, 7-98
T1-08-0404G
Page No. 13 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
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.
Tack weld the crowned seam joint at regular intervals with a tack of 5T and pitch
of 25T.
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.
Weld radial seam at TE according to welding sequence plan.
Align, adjust and tack weld radial seam at GE.
Weld radial seam at GE according to welding sequence plan.
Weld crowned seam joint.
Align shell courses on joint strips and tack weld,
Weld on joint strips from center & ends of shell plate.
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.
Check welds according to specifications.
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Preparation of HP rotor for alignment.
Preparation of IP rotor for alignment.
Preparation of LP rotor for alignment.
Alignment of LP-IP & HP rotors.
Reaming, honing of the coupling holes.
Balancing of coupling bolts weight.
T1-08-0404G
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STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
T1-08-0404G
Page No. 16 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
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.
T1-08-0404G
Page No. 17 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Record all the radial and axial clearances of the LP casing without coupling
the LP-IP rotor. Variation if any in radial or axial clearances are to be
corrected/approved at this stage.
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.
T1-08-0404G
Page No. 18 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
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.
Check swing check value of the HP rotor with alternate bolts in position. The
above value must be within the prescribed limit only otherwise a
correction must be carried out at site in consultation with designer.
Ensure free movement of rotor on their bearing. Do not rotate the
is tight during its rotation.
Ensue that the coupling holes are
enlargement of holes.
rotor if it
Ensure HP-IP-LP rotor radial run out after tightening with alternate clearance
bolts. Release the couplings for reaming / honing of couplings.
In case of spring loaded TG decks, refer alignment procedure
0909G
T1-08-
T1-08-0404G
Page No. 19 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
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.
T1-08-0404G
Page No. 20 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
rotor collar by moving the rotor in +/- direction during its hand rotation.
Following points are to be taken care during colour matching.
Thrust bearing must be axially locked with the help of axial keys during the
colour matching of the pads. Axial keys to be fitted while finalising the
alignment of thrust bearing with rotor collar without pads.
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.
Colour is to be applied on the thrust collar of the rotor.
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.
T1-08-0404G
Page No. 21 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
T1-08-0404G
Page No. 22 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
Ensure feeler tightness of the parting plane joint of both the casing.
Check/record all the radial and axial clearances of 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.
T1-08-0404G
Page No. 23 of 24
STEAM TURBINE
500 MW
ERECTION PROCEDURE
ERECTION
During the boxing up of the LP outer casing following points are to be taken
care.
Roll check of LP inner casing including the fitting of key, packers etc. must be
finished.
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.
Ensure feeler tightness of bursting diaphragm flange joint before boxing up of
the casing.
Ensure proper assembly of parting plane rubber cord.
T1-08-0404G
Page No. 24 of 24