Erection Manual Hydro-1

ERECTION MANUAL
FOR
5X55 MW

HYDRO TURBINE
FOR
ALMATTI HYDRO POWER STATION
KARNATAKA POWER CORPORATION LIMITED

BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION

CONTENTS
S.NO -

DESCRIPTION

PAGE NO.

1.

STORAGE AND HANDLING INSTRUCTINS

3 - 11

2.

GENRAL GUIDELINES FOR ERECTION

12 - 24

3.

TECHNICAL DATA

4.

ERECTION OF EMBEDED PARTS

25- 28

5.

ERECTION OF FOUNDATION PARTS

29 -36

6.

TURBINE ASSEMBLY

37 - 63

7.

AUXILLARIES

64 - 67

8.

ANNEXURE -(LOGSHEET) `

68

STORAGE AND HANDLING INSTRUCTIONS
1. GENERAL
1.

The instructions given here are to serve as compendium for Storage
and handling of the Hydro Turbine components.
The technology of packing and also design of components are
constantly being improved and hence the instructions given here are
subject to modifications. Effort has beer, made to cover as many
aspects as can be foreseen at the moment. The aim of proper storing
and handling is to ensure trouble free erection and operation. It has
been pre-supposed that the operators and supervisors who will handle
these are conversant with general engineering practices and
sufficiently skilled in material handling.

2.

The following publications by British Standard Institute will be most
helpful.

1.2
1.2.1

i)

B.S. 113-1967 - Packing Code Sections 1 TO 6 and section 19.

ii)

B.S. Hand Book No.4 part 1 and 2 'Lifting Tackle'.

RECEIVING AND UNLOADING
The components are packed for their safe transportation -from the
manufacturers works to the site and this packing is unsuitable for long
time storage in open air after the packages have reached the erection
site.

1.2.2

Before unloading a packing case from the carrier the following
instructions painted on the packing case should be noted.

1.2.3

(i)

Weight of the package.

(ii)

Marking showing "THIS SIDE TOP".

(iii)

Marking showing the "SLING POSITION".

For all major components, lifting arrangement drawings are supplied.
These should be consulted while lifting these components.

1.2.4

Suitable lifting gear should be selected. The lifting tackles which are
properly certified by appropriate authority about load carrying capacity
should only be used. All tackles should be properly maintained. If the
sling marks are not provided on any of the packing for lifting, the sling

should preferably make an angle not more than 30 deg. to the
vertical, and in no case more than 45 deg., while lifting the packing.
1.2.5

Lifting should be done without jerks and impacts.

1.2.6

While handling the packing, the warnings indicated by markings and
inscriptions on the packing boxes such as "HANDLE WITH CARE".
"THIS SIDE TOP" "NOT TO PUT LOAD ON THE TOP", "SLING
HERE" etc. shall be strictly observed.

1.2.7

On receipt of the equipment check them with the shipping list. Any
omission and damages should be reported back

to BHEL

immediately. This checking should be preferably done in the presence
of BHEL's representative posted at site. At the time of inspection the
case should be opened carefully so as not to destroy the packing
material in the process to that it can re re-used.
1.2.8

Protective coating applied on machined surfaces should not be
disturbed. The plastic covering should be put back carefully after
inspection of the component. Some packing cases may contain VCI
(Volatile Corrosion Inhibitor) coated paper, which lets off the vapour
that prevents corrosion of the parts inside the packing case. This
should not be thrown away as long at it is effective. Absence of odour
from the paper indicates loss of effectiveness. Silica Gel and such
other chemicals kept in the box as desiccants and indicators should
also be left in the box. The case should be restored to its original
state as -far as possible.

1.3

STORAGE
The equipment should be accommodated in permanent place of
storage within a week after arrival at destination.

1.3.1

The warehouse or the covered area where the equipment is to be
stored should be clean, dry and well ventilated. It must have been
pretreated with pesticides insecticides against growth of fungus and
other micro-organism.

1.3.2

The cases should be arranged in neat stacks away from walls and at
least 100 mm above floor level preferably on rail sections, and also so
far as possible in the sequence of requirement of the parts for erection.
Adequate gangways are to be left for inspection and cleaning. It is also
recommended to repaint weight, upright position indication etc. on the
side exposed for inspection.

1.3.3

To prevent distortion the heavy part and other large assemblies should
be kept on even platform. The articles weighing 10,000 kg and above
should be arranged in a single tier. Parts weighting up to 5,000 kg may
be piled up to a height of 2.5 meters. Small and medium sizecomponents are recommend recommended to be stored on shelves.

1.4

GUIDE PADS

1.4.1

Guide pads supplied by BHEL have thin lining (2 to 3 mm) of tin base
babbit metal chemically bonded to a steel backing. The pads are
polished to high surface finish.

1.4.2

The babbit metal is quite soft and can be easily scored by ferrous
material. These pads should be stored in such a way as to prevent
abrasion, scoring etc. These pads must not be stacked one over
another.

1 .5

FABRICATED COMPONENTS

1.5.1

All these items are generally fabricated from mild steel shot blasted
and painted. The machined surfaces however are treated with
corrosion protective chemicals. As these chemicals are to be removed
before assembly, they are necessarily of temporary nature and can be
easily removed. Sometimes, in addition to this, aluminum foils or

plywood is used to protect against mechanical damage.
1.5.2

As soon as the components are received at side they should be
examined for rupture of preventive (TRP) film given at works. It is
recommended that either a touch up work is done or complete new film
of TRP is applied detailed instructions refer Appendix ‘B’.

1.5.3

It is recommended that films are replaced twice a year, preferably
before and after prolonged rainy periods.
Oil and grease do not protect surface adequately. BHEL do not
recommend their use as rust preventives.

1.6

PIPE WORK
Before the pipes and pipe works are sent to site, the pipes are pickled
and coated with rust preventive coatings. Small bore pipes are plugged
and large bore pipes are covered with flanges.
Drg. No. 32630301005 manufacturing specification for water piping.
Drg. No. 32603031006 manufacturing specification for oil piping.

1.7

INSTRUMENTS
Packing cases containing instruments, relays, motors, etc., are marked
'fragile'. Jerks and impacts should be avoided in handling these. These
cases should be fully opened and inspected for any damage on arrival.
The repair and replacement of instruments takes a long time. It is
recommended that all the instruments are checked for calibration. The
instruments should be repacked giving adequate cushioning. The
instruments could also be stored individually without the packing cases,
but on properly cushioned bases and with adequate protection against
falling objects, accidental impacts etc. All instruments should be stored
in a vibration free area.
For the convenience of site staff a list of major parts and assemblies of
hydro turbine with the recommended storage conditions for them is
given is Appendix "A".

1.8

ASSISTANCE FROM BHEL
If any problems arise in handling and storage of all components
supplied by BHEL, and not already covered in these instructions. BHEL
would be pleased to advice and offer suitable assistance.

APPENDIX 'A'
RECOMMENDED STORAGE CONDITIONS
Storage Condition

Description of Assembly

Fully protected covered area

Oil coolers, shaft and oil sleeve
assembly. Pipe assembly, supports,
valves,

flexible

housing

etc.

for

lubrication unit, pump motor unit.
Semi protected covered area

Guide

bearing

housing,

Valves,

elbows, unions, couplers, foundation
Bolts-studs-washers,

Battle

tray

Assembly, flooring, cooling Water/oil
pipes, hardware

NOTE: SEE BOOKLET FOR INSTRUCTIONS ON HANDLING STORAGE
AND PRESERVATION OF HYDRO TURBINE EQUIPMENT AT SITE.

APPENDIX 'B'
2.0

PROTECTION OF FERROUS COMPONENTS WITH TEMPORARY
RUST PREVENTIVE SYSTEM

INTRODUCTION:

All components dispatched from BHEL Bhopal would
have been given protection against rust by application of
one of the following points. However if any site
application is necessary due to long storage, following
guidelines should be kept in mind.

2.1

Materials

2.1.1. For site use BHEL recommends the following Temporary Rust
Preventives (TRP).
a) Non-drying Type (Pigmented) BP 55191
b) Drying Type (Pigmented) AA 55155
c) Drying Type (Black) AA 55154
2.1.2 Non -Drying Type (Pigmented) BP 55191
This can be applied with brush resulting in soft non-drying film. This
provides protection for a period not exceeding 4 to 6 months. This can
be removed with white spirit. Because on non-drying nature of the film,
it runs the risk of getting wiped off accidentally and exposing that area
to corrosion. Hence more care is required during storage.
2.1.3 Drying Type (Pigmented) AA 55155
This can be applied with brush resulting in thin dry film, which can be
removed with white spirit Xylol or Toluol. It would provide protection for
a period not exceeding six months.
2.1.4

Drying Type (Black) AA 55154
This can be applied with brush resulting in a thin dry film which can be
removed with white spirit. It would provide protection for a period of 12
months. It is good for outdoor applications.

2.2

Other materials which would be required in the process are:
a) Xylol

b) Toluol
c) Mineral Turpentine (White Spirit)
d) Derusting Solution (Rust Removal) BP 55193
3. 0

SURFACE CLEANING
Before any TRP is applied on any metal surface the surface should be
free from old TRP, rust, grease, moisture etc. It may be emphasized
that the effectiveness of the TRP is reduced or even nullified if the
surface is left contaminated.

3.1

Remove the old TRP with the help of white spirit.

3.2

Remove the rust spots using sufficient quantity of derust solution
rubbing with clean cloth. Clean the surface with cloth soaked in water.
In case the surface is still not clean, repeat the process. Finally remove
the residual acid from the surface with the help of wet cotton otherwise
it may cause further Corrosion.

3.3

Dry the surface with the help of hot air blower.

3.4

Wipe off the surface with clean cloth having small quantity of
uncontaminated white spirit. Allow the solvent to evaporate. The
surface is now ready for TRP application.

4.0

TRP APPLICATION
The application has been classified into four categories viz., A, B, C&D
keeping in view the status of finish and extent of protection desired.

4.1

Category ‘A’
Journal faces, highly finished surfaces (better than 0.8 microns) such
as thrust face, bearing surfaces of Shafts.

4.2

Category 'B'
Large fabricated items having machined surfaces such as Guide
Bearing Support Ring, Vapour Seal Assy, Oil Retaining Sleeve, mating
surfaces, shaft flanges.

4.3

Category 'C'

All fasteners and threaded portions excepting in such cases where the
job has already a protective film each as plating, galvanizing etc.
4.4

Category 'D'
Small machined components & other components not defined above.

5.0

TRP SYSTEM OF APPLICATION

5.1

Jobs classified in Category 'A' and ‘B' will have 3-coat system as
detailed below.

5.1.1

After cleaning, apply one coat of TRP AA 55155 and allow it to air dry
for 12 hours inside the store.

5.1.2

Clean dust from the surface and apply a coat of TRP AA 55154 and
allow it to air dry for about 12 hours.

5.1.3

Apply second coat of TRP AA 55154 and allow it to air dry.

5.2

Jobs classified as Category 'C' will have 2-coat system as detailed
below.

5.2.1 After cleaning apply one coat of AA 55154 on non-threaded portion and
a liberal coat of BP 55191 on threaded portion. Allow if to air dry for 12
hours.
5.2.2

Apply second coat of TRP AA 55154 on non-threaded portion.

5.2.3

Fasteners of small size, having no other protective film such as plating,
galvanizing etc. after cleaning, shall be given a liberal coat of BP 55191
TRP on threaded and non-threaded portion.

5.3

Jobs classified, as Category ‘D’ will have two-coat system of TRP as
detailed below.

5.3.1

After cleaning apply one coat of AA 55155 and allow it to air dry for 12
hours.

5.3.2

Apply second coat of AA 55154 liberally and allow it to air dry.

6.0

PRECAUTIONS

6.1

TRP should be stirred well in the original container so as to make a
homogeneous mixture of its constituents.

6.2

Container and brush must be cleaned after application with white spirit
before keeping for next operation.

6.3

During the drying period, the wet film should be protected from,
deposition of dust particles by providing an umbrella of polythene
sheet.

6.4

Protections, given for TRP film, such as Aluminum sheet, plywood etc.
should be replaced after application of the TRP. The surface coming in
contact with the job should be given a liberal coat of AA 55154.

6.5

Normally after an interval of six months, the surface of TRP coated jobs
shall be examined for any damage, corrosion spots etc. the repair
should be done and TRP System applied.

6.6

All materials specified above can be ordered on BHEL.

GENERAL GUIDELINES FOR ASSEMBLY AND ERECTION
1.

POWER HOUSE AXIS
Customer shall provide axis of powerhouse and elevation. Established
centerline and datum shall be made available on steel plates embedded in
concrete nearest to respective unit in powerhouse.

2. CONCRETING AND GROUTING
2.1 Concreting does not come under BHEL scope of work. However,
customer should ensure that following precautions are taken prior to
and during concreting.
2.2 For good bonding, old concrete surface should be made rough and if
required should be chipped.
2.3 All surfaces should be cleaned and washed with air water jet.
2.4 Concreting shall be done in steps / lifts.
2.5 Concrete foundations, pedestal of equipments are to be chipped and
made even to achieve surface contact for better load transfer to
foundation.
2.6 Recommended setting time is allowed before taking up further works.
2.7 During concreting, vibrator must not touch any embedded or machine
parts.
2.8 Grouting wherever required shall be done from bottom upwards as
slowly as possible. Grouting pressure should not be more than
specified at relevant places. Grouting shall be stopped when grout
material flows out from other grouting holes provided for each space,
surrounded by ribs.
3. MEASUREMENT AND RECORDS
3.1 All measurements shall be taken as per the checklists / log sheets of
field quality assurance and recorded.
3.2 For spiral casing with stay ring, measurement shall be taken before
and after concreting. In case of any deviation corrective action shall be
taken.

3.3 Final log sheets shall be prepared at each stage of erection work and
signed by representatives of BHEL and customer.
3.4 Even though erection tolerances are given, efforts shall be made to
achieve best possible results.
4. UNPACKING AND CHECKING OF PLANT EQUIPMENT
4.1 All materials shall be unpacked and checked well in advance of
erection work. In case of any damage / shortage, suitable action in line
with QAM/SP shall be initiated to inform concerned agencies. Storage
and preservation of materials shall be ensured as per manufacturer
instructions.
4.2 All rubber products eg. Cup seals, O-rings etc. are preserved till their
use, in chalk powder / water container with water replacement every
week / water soaked saw dust.
5. WELDING
5.1 Welding is carried out by a qualified welder.
5.2 Recommended electrodes are used wherever specified.
5.3 Edge preparation is checked / prepared wherever required as per
drawing.
5.4 Surfaces are cleaned thoroughly before starting welding, surfaces
must be free from foreign materials such as grease, oil, paints etc. for
a distance of at least 20 mm from weld joint on either side.
5.5 Electrodes are suitably baked in oven prior to their use to 300 C at
least for two hours / as per manufacturers guidelines.
5.6 Proper root gap is maintained for welding to avoid undercut, over laps,
abrupt ridges and valleys.
If the gap is more than 5 mm packing strips are provided to minimize
shrinking and welding deformation. These shall be removed before
starting seal welding from other side.
Preheating / post-heating of surfaces / stress relieving of weld joints is
carried out wherever necessary as per technical requirements.

5.7 After root run completion of welding dye penetrant testing is carried
out and corrective action taken.
5.8 Wherever circumferential welding is involved, welding as per sketch
no. 1 is followed for making root run.
5.8.1

Mark zone of approximately 300 to 400 mm length as shown.

5.8.2

Complete welding in various zones starting simultaneously in
opposite quadrants.

5.8.3

After this, welding may done starting from two or four points and
proceed continuously. In other joints skip / step welding as
shown in sketch no. 2 may be followed to minimize deformation
of equipments.

5.9

Before starting seal welding on the other side, gouging / or grinding
is done and dye penetrant is carried out.

5.10 All site weld joints of stayring and spiral casing are radiographed or
UT done as per technical requirements of concerned drawing.
5.11 After completion of site welding and grinding painting of effected
areas is to be done.
5.12 In case welding is provided in pipe works, edge preparation and
welding is carried as per drawing requirements.
6.

RUBBER CORD SCARF / STRAIGHT JOINTING
6.1 Area of each groove equipments is measured / calculated. Rubber
cord of 80% to 90% of the groove area is selected.
6.2 Cut the cord as per length required including scarf / straight joint. In
general it is recommended to keep the length of cord 1% less than the
actual requirement.
6.3 Prepare by cutting or / and grinding as shown in sketch no. 3.
6.4 Clean the ends and make joint with suitable adhesive, eg. Anabond,
Elfy, etc.
7. USE OF LUBRICANTS
7.1 During assembly of close fitting parts, moving or sliding parts, a thin
coat of grease is applied.
7.2 On the other joints of sealing surfaces, a thin coat of white lead / holdtite may be applied.
8. TIGHTENING OF FASTENERS
8.1 On the threads of heavy duty fasteners, it is recommended to apply a
thin coating of anti seizing compound i.e. molybendenum disulphide or
graphite grease in order to prevent scratching or seizing at the time of
tightening or loosening.
8.2 While tightening the fasteners, be sure to proceed symmetrically and
uniform, so that there is no unbalanced tightening in the joint. The
tightening wherever specified should be followed. After fully tightening
the fasteners these should be locked as called in the drawing.
8.3 All thread portions and fasteners are proved in advance for checking
healthier threads. If not, rectified suitably for obtaining smooth threads.
9.

ASSEMBLY OF EQUIPMENTS
9.1

Before taking up any assembly, check all items of the concerned
drawing are available. Check for any damaged components and
rectify if possible after obtaining concurrence from concerned
manufacturing unit.

9.2

Check for all technical requirements of drawings to be satisfied at
site and ensure their compliance.

9.3

Check for all concessions /deviations raised at shop if any to be
taken care at site and ensure compliance.

9.4

Check for all test results of shop wherever necessary.

9.5

Check for PO number, assembly match mark and axis marking for
each assembly.

9.6

Ensure that individual components are cleaned & are free from burrs
and scratches.

9.7

Check for special lifting arrangements of assembly / sub assembly, if
any and ensure its availability.

9.8

Check for shop dowels.

9.9

Temporary plugs / protections provided should be retained till final
assembly.

9.10 Blow compressed air to oil and grease ports, load grease ports with
grease and plug them temporarily.
10. CONFIRMATION BEFORE STARTING ERECTION / ASSEMBLY
WORK
10.1 Confirm availability of all tools and tackles required for erection
works.
10.2 Confirm

availability

of

reference

drawings

and

technical

documentation related to the project.
10.3 Confirm customers certified centre line and established datum
available on embedded plates on the concrete nearest to the pit.

10.4 Confirm availability of all connected equipment’s, instruments
required for erection.
10.5 Ensure installation of generator assemblies with reference to Radial
line of assembly.
11. PREPARATION OF FOUNDATION BLOCK OUTS
11.1 Check the foundation block outs dimension and locations, if
necessary carry out chipping of foundations to required dimension
and elevation.

B.

Welding & Cutting

1.

Use proper protective clothings, welding glass to avoid burn injuries
due to welding spatters, hot welding slag arc flashes etc.

2.

Ensure proper earthing of work & welding machine to avoid electric
shock.

3.

Never look at welding arc without using welding dark glass.

4.

Welding area should be properly ventilated to minimize air pollution in
the surrounding area.

5.

Fire extinguishers, sand etc, should be available nearby.

6.

Store gas cylinders away from "Sources of Heat" Over Furnace, direct
sun rays.

7.

Store gas cylinder in well-ventilated place.

8.

Use rubber hoses correctly as per coding.

9.

Oxygen green or Black house. Acetylene Red hose.

10.

Ensure against leakage of gas from torch, hose valves Regulators etc.
Use proper pipe clips. Periodical checking of pressure gauges of
regulator to be done.

11.

No flammable material like Petrol, Oils Dyes Acids Enamel paints and
Varnishes etc, be lying in the area where cutting or welding is being
done.

(c)

Lifting Tackles

1.

Do not subject wire rope beyond safe working loads.

2.

Periodic inspection of ropes and safe load testing be done.

3.

Store ropes properly to avoid kinks.

4.

Periodic greasing of ropes should be done to avoid rusting and
decrease friction.

5.

Periodic testing of 'D' shackles, turn buckles, Pull lifts and chain pulley
blocks be done.

6.

Avoid wire ropes coming in contact with sharp edges while lifting.

(D)

Cranes

1.

Never stand under heavy loads.

2.

Do not keep the load suspended for more time than absolutely
required. For this, plan your activity well in advance.

3.

Lifting of loads shall be started slowly and erratic movements avoided.

4.

Grease the wire ropes regularly.

5.

Periodic checking of electrical controls and brakes, gearbox to be
done.

6.

While giving signals to crane operator standard signals with which
operator is conversant be given by one man.

7.

Crane should be regularly maintained as per its maintenance schedule.

(E)

Rotating Small Hand Tools
(Like Grinding, drilling machines)

1.

Guards above moving parts should be in position.

2.

Use proper protective clothing.

3.

Use safety appliances like goggles hand gloves, aprons.

4.

Avoid standing in -front of the wheel or cutting tool, whiie in motion.

5.

Do not apply excessive pressure on cutting tools to quicken the
process.

6.

Tool/Grinding wheels be secured properly.

7.

Correct speed be ensured of rotating wheels.

8.

Ensure electric hand tools are free from electric shock.

F.

Acids and Alkalies

1.

Never add water to Acid for making dilute solution. Always add Acid to
water.

2.

Never handle any acid or alkali with bare hands and without protection
to eyes.

3.

Use acid proof rubber gloves, gum boots, rubber aprons and goggles
as per Job requirements.

4.

Whenever there is any acid or alkali burn, wash off as quickly as
possible with a large quantity of clear water and then rush to doctor.

SEQUENCE OF ERECTION
A.

Establishment of C/L & Bench mark.

B.

Pier nose Liner

C.

D.T. Elbow Liner.

D.

D.T. Cone

E.

1st stage Foundation, embedment & pipes

F.

Stay ring

G.

Spiral Casing.

H.

Welding & Radiography

I.

Test Cylinder & Cone

J.

Pressure Testing & Dismantling Test Cone & Cylinder Runner envelop
& Matching Piece. (Make up piece)

K.

Concreting

L.

Second stage foundation, embedment & pipes, pit liner assembly.

M.

Barrel concreting, foundation pipes.

N.

Rotor assembly & Stator assembly in E.B.

O.

Runner assembly runner & shaft assembly pr. test. Trial assembly of
G.V with pivoting & outer Top Cover.

R.

Lowering of Runner & Shaft assembly with Inner top cover final assy, of
Guide apparatus.

S.

Auxiliaries & Governor piping

T.

Governor oil piping, G.V. Servo, piping & other Auxiliaries.

U.

Feed back Mechanism.

V.

Lower Bkt. Foundation stools, stator foundation stools

W.

Lower bkt. assembly & lowering, Centralizing.

X.

Stator lowering, Centering, Air cooler assembly, piping.

Y.

Spring assembly. Thrust pad assembly, H.S. Lubrication.

Lowering of shaft after, fixing servo tube.

Z.

KPCL – Almatti Dam Power House
2.6.0

HYDRAULIC AND TURBINE PARAMETERS

2.6.1

The hydraulic parameters of the project are as detailed below
55MW

1.

Full reservoir level FRL:

EL 519.60m (present)
EL 524.256 m (future)

2. Minimum draw down level

EL 511.16m

for power generation
3. Maximum gross head

30.55m (present)
35.206m (future)

4. Minimum gross head

18.91m

5. Rated head

26.60m (present)

6. Direction of rotation

Clockwise when viewed from top

7. Service bay level

EL 504.50m

8. Type of turbine

FULL KAPLAN

9. Discharge at rated capacity

To be furnished

10. Maximum discharge

252.48 cumecs

(overload capacity)
11. Rated speed

115.38 rpm

12. Runner diameter

5650 mm

13. Penstock diameter
(a) Already embedded

7m

(b) Extended portion

7.80 m

14. Spacing between penstocks
(already embedded)
15. Governor time

25 m

(a) Effective closing

7 sec

(b) Effective opening

15 sec

16. Maximum instantaneous

35%

pressure rise (% of max. static head)
17. Minimum time required

13 sec

for full load acceptance
18. Maximum speed rise

40%

(% of rated speed)
19. Range of speed

50 ± 5 Hz

adjustment device
20. Speed droop control :
(a) Permanent

0 to 10%

(b) Temporary

0 to 100%

21. Length of penstock :
(a) Already embedded

38.95m

(b) Extended portion

47.42 m

22. Elevation of deepest :
Draft tube point

EL 466.72m

23. Turbine floor level

EL 490.00m

24. Distributor centre line setting

EL 484.90m

25. Centerline of runner

EL 482.66

GUIDE APPARATUS TECH DATA
% GUIDE VANE OPENING

100%

G. V. OPENING 0 (mm)

555 ± 10

 In degree

50°

SERVOMOTOR STROKE IN MM

811.3

CHORD ON OUTER DIA 3890 OF REGULATING

654.7

RING

A1.

Shaft leveling after oil filling.

A2.

Lower Rotor, Couple Shaft, Hydraulic Bolt Tensioning, Break/Jack
piping

A3.

Generator Alignment

A4.

Coupling & combined alignment

A5.

Servo tube alignment

A6.

Slip ring alignment.

A7.

Centralizing w.r.t Runner and Locking.

A8.

Guide pad assembly, Turbine, LGB, UGB

A9.

Release lock, close bearing.

A10. Oil vapour sleeves & piping.
A11.

Top & Bottom air Guide assembly.

A12. Grouting of Stools
A13. C.W. piping to bearing/Compressor, Air pipe lines.
A14. Oil header assembly
A15. Speed sensor Assembly
A16. Flooring & Top dome assembly
A17. Cabling inside panel
A18. Control & Metering panel, MMI, Auto Sequencer panels, SEE, MCCs,
Aux. Transformer, instrumentation, inlet gate, etc.
A19. Tray work, cabling, checking & termination.
A20. Loop checking, pre commissioning, commissioning.
A21. T.G. panel, Governor panel Co2 system etc.
A22. All other Miscellaneous work prior to spinning like, grouting, dowelling
etc.

Sl. No

DESCRIPTION

PAGE NO:

Erection of Embedded Parts
1.

First Stage Foundation Pipe

23

2.

Field Efficiency test pipes

24

3.

Pier nose liner

25

4.

Draft Tube

26

Embedded Parts
Embedded Pipe in First Stage
(A)

Pre-Erection Checks.
(i) Check for availability of all the items as per relevant drgs & bill of
material and clean them.
(ii)

Check that all the necessary tools, equipment & material
required are available at site.

(B)

Erection.
(i)

Pipes to be erected.
(a)

Draft tube drain pipe.

(b)

Spiral drain pipe.

(iii)

Position above pipes as per drawing dimensions & elevations.

(iv)

Weld the pipes as per details given in drawing.

(v)

Ensure proper clamping of pipes so that they remain in the
same position during concreting.

(vi)

Hydraulically Test the pipes as per Drawing.
Blank the open ends of the pipes with M.S plates. Tack weld at
minimum 4 points to lock.
Reference Drawings: 02010414201
Pipes & Embedment in I Stage

Field efficiency test for pipes
1.

Field efficiency and discharge measurements are to be made for all 5
units of 55 MW units as per drg.

2.

Obtain datum line of penstock.

3.

Bends of St. Steel pipes to be made at Site.

4.

Mark Bosses on penstock DT liner / spiral casing and weld suitably.

5.

Erect bend pipes and position support.

6.

Pressure test pipes as per values given in drawing.

7.

Clamp supports and put covers. Hand over for concreting.

8.

After concreting check pipes for any blockage concreting.

9.

Embedded pipes for field efficiency test drg. No. 0-201-11-14201.

Pier Nose
1.

Lower Pier nose assembly using winches wire ropes or suitable crane
then check level and elevation.

2.

Use shims / packing plate for achieving required elevation.

3.

Check center-to-center distance and align.

4.

Fix foundation bolts and tighten.

5.

Fixing of Anchors.

6.

Final checking of alignment and verticality.

7.

Hand over for concreting.
Tolerance:

(a)

Vertically 1 .mm/metre.

(b)

Elevation within ± 2 mm.

Ref. : Installation of pier nose liner Drg. No. 02010314201.

Draft Tube Elbow Liner
1.

Transport D.T. Knee liner segments in Sequence.

2.

Check Unit Nos. Match marks etc.

3.

Check level of pedestal/ Steel supports.

4.

Lower bottom most - segments and match.

5.

Arrange all bottom, top, left side, right side segments and assemble
them complying with elevation w.r.t. relevant drgs.

6.

Stich welds assembly.

7.

Check dimension elevation, matching and then clear for full weld.

8.

Weld as per relevant Standards

9.

Dye tests the root run.

10.

Flush grind final run, align, tighten, H.D. Bolts and Turn buckles lock,
erect drain box assembly & connect DT drain pipe & weld.

11.

Hand over for concreting.

Reference drawing of installation of DT liner Drg. No. 0-201-02-14201
Draft tube water path 1-201-00-65602.

Erection of Draft Tube Cone :
1.

Lower two bottom cone segments, align with DT liner and Tack weld.

2.

Lower two top segments of cone and align.

3.

Check elevation of DT cone as per drg. Correct if necessary.

4.

Check alignment of cone w.r.t. X & Y axis within 2 mm. Top center of D.T.
cone to be in line with D.T. liner center within ± 2 mm.

5.

Measure the inner diameter of cone at the top. If it is not as per drg.
correct it.

6.

If all readings are ok, then tack weld all turn-buckles.

7.

Weld the joints as per relevant standards and dye test the root run.

8.

Release for concreting up to casing of piers for spiral casing and stay
ring.

Reference drawing: Installation of D. T. cone. Drg. No. : 0-201-01-14201.

SL.NO

DESCRIPTION

PAGE NO

Erection of Foundation Parts
1.

STAY RING

29

2.

SPIRAL CASING

30

3.

RUNNER ENVELOP

31

4.

PIT LINER

32
STAY RING

(A) PRE ERECTION CHECKS
(i)

Check for availability of all the items as per drawing.

(ii)

Check for any damage during transportation & repair if necessary.

(iii)

Check all the pier details as per drawing.

(iv)

Check & prove threads on joint bolts & nuts.

(v)

Establish center line (x, y Axis) & Datum elevation given by the civil
wing.

(vi)

Check welds preparations for site welding joints as per drawing.

(B) ERECTION
(i)

Transport of stay ring.

(ii)

Assemble in service bay and heat and tighten the Joint bolts to achieve
elongation as per drawing.

(iii)

Use the sling given as per drawing and lift.

(iv)

Lower the Stay ring on stools, so that stay ring pedestal are resting on
the stool. Align center & level with respect to station, Center Line, using
hydraulic Jacks/Mechanical Jacking screws.

(v)

Ensure Tightness of joints 0.05mm feeler gauge should not go.

(vi)

No step at joints on top & bottom machined surfaced after joining.
Check radius at top & bottom machined bores.

(vii)

Check locking of Joint bolts & Nuts.

(viii)

Seal welding of Joints to be done as per drawing requirement. Conduct

NDT tests as per drawing requirement.
Tolerance : Ref drawing :
Installation of stay ring

stay ring installation Drg. No. : 02020114201
Log sheet = L-02

SPIRAL CASING
(A) PRE-ERECTION CHECKS.
(i)

Check for availability of all the items as per drawing.

(ii)

Check for any damage during transportation & repairs if
necessary.

(iii)

Check and prove threads on holding down, bolts & jacking bolts
& other hardware.

(iv)

Check weld preparation for site welding joint as per drawing.

(B) ERECTION
(i)

Assemble the spiral segments as per drawing & ensure that gap
at joints in axial or radial direction is 2 to 5m.m

(ii)

Match the spiral members with top & bottom contour of stay ring
& center line marked on spiral member with reference to center
line of stay ring (± 2mm).

(iii)

Weld the spiral segments as per technical requirements given in
the drawing.

(iv)

Dye check the weld seams for any surface defects in the plate.

(v)

Back gouge, grind & dye check for seal run, complete the
sealing run.

(vi)

Radiograph and ultrasonic Test for all butt Joints to be carried
out as per drawing requirement.

(vii)

Lower the test cylinder and fix it in position.

(viii)

Place test cone and weld with spiral inlet.

(ix)

Carry out the Hydraulic testing of spiral casing at pre test
pressure and time as given in drawing.

(x)

After successful completion of Hyd. Test, remove test cone &
test cylinder.

(xi)

Complete the installation of holding down bolts, anchors,
wedges, & lock all the hardware.

(xii)

Check the leveling & stay ring.

(xiii)

Carry out erection, welding and NDT of inlet pipe as per
drawing.

(xiv)

Recheck the alignment leveling of stay ring before handing over
for concreting

1) Installation of spiral casing drg. No. 02020214201
2) Arrangement of spiral testing 02025214201
3) Installation of inlet pipe to spiral casing drg. No. 02020414201
Ref.Drawing : Log sheet L-02
Installation of Stay ring.
Log sheet L-03
Installation of Stay ring & Spiral inlet pipe
Runner Envelopes
A. Pre Erection Checks.
1.

Trial Assemble two halves at service Bay.

2.

Check diameter.

B. Erection.
i.

Runner Envelope to be lowered, after lowering for Ist out before stay
ring.

ii.

Centering w . r . t . axis of stay ring and check diameter.

iii.

Fastening, anchoring and welding with stay ring.

iv.

Welding of make up piece with D. T. cone & Runner envelope.

v.

Dye testing of seal welding of joint flange to be done.

vi.

Spider assembly to be carried out before concreting, as per
requirement of drawing.

vii.

Recheck: the centering of Runner envelope after concreting.

Runner envelope installation
Ref Drawing no. 02020614201 Log sheet L-04
Installation of runner chamber

PIT LINER
ERECTION
A. LOWER THE PIT LINER SEGMENTS
1. The mechanical surfaces for fixing the servo motors are equidistant from X
& Y axis (with tolerance as per drawing) & are vertical. 1 mm. per meter
2. Top dia of pit liner (± 5 mm)
3. Welding to requirements as per drawing.
4. Welding of anchor plates.
5. Installation of pipes / Pipes sleeves for routing of air, water and other pipe
lines. Also check that embedded pipe carrying in this state of concreting
are installed and the free ends are blanked off by welding metal plate.
Ensure placement of sufficient sleeves for routing cables etc also.
Ref Drawing: Installation of pit liner Drg. No. 02020714201
SL. NO
1.

DESCRIPTION

Runner assembly in Erection Bay, testing &
Testing of Cone assembly

2.

Pivot ring assembly

3.

Outer Top Cover assembly

4.

Trial assembly of G.V with outer
Top Cover & dismantling

5.

Guide Apparatus Assembly

6.

Runner & shaft assembly with outer top cover

7.

Lowering of runner assembly with
inner top cover &final assembly & centering

8.

Installation of Regulating Ring

9.

Installation. of G V. servomotor

10.

Guide Bearing

11.

Shaft seal

PAGE NO.

12.

Oil-Header

13.

Governing Equipment

14.

Installation of Metering Instruments

RUNNER ASSEMBLY
1.

Check availability of all materials as per drawings.

2.

Perform visual inspection for any damages, report to unit if any
abnormality is noticed.

3.

Check the match markings during dismantling (if the runner is received
at site in assembled condition).

4.

Perform overhauling internal checking of runner as per drawings.

5.

During reassembly of runner as per drawing, check the following:
a) Ensure usage of proper / suitable settings for lifting & twining of runner.
b) Check the machined surfaces of piston, servo motor cylinder, sliding
blocks and other components against any scratch, dents etc.
c) Check that the rubber items such as 'O' seals, sealing, cup scales etc
are in good condition.
d) Check that the threaded holes and fasteners are not damaged.
e) Check the grooves and rubber cords for their sizes.
f) Check correct joining and assembly of rubber cords and other seals.
g) Check the free movement of sliding blocks.
h) Check that the locking of Bronze Bushes are as per drawing.
i) Check that the pre stressing of fasteners is done as per drawing
reference.
j) Check that the locking on laterships, washers, plugs and valves are as
per technical requirements/details of drawing.
k) Assemble runner shaft and servo tube with runner as per drawing
l) Elongate coupling bolts as per the values mentioned in the drg.

m) Measure and record the clearance between runner hubs & blade, it
should be as per drawing value.
n) Perform testing of the Runner as per test procedure technical data
provided in the drawings supplied by manufacturing unit.
Drawing to be referred
1. Tools tackless for runner shaft drg. No. 02045114201
2. Runner assembly drg. No. 02040714201
3. Shaft arrangement drg. No. 02050114201
4. Arrangement of all tubes of runner servomotor drg. No. 2050314201
5. Testing devices for runner & shaft drg. No. 02045214201
6. Log sheets:
1) Elongation of fitted bolts between runner & shaft L-06
Test certificate for KAPLAN runner assy, L-05.

RUNNER ASSEMBLY
Overhauling, Shaft assembly, Hyd. Testing
A. KAPLAN RUNNER
1. Runner of a Kaplan turbine is dispatched to site, fully assembled or partly
assembled and partly loose depending on its overall size / transport
limitations. Partly assembled runner comprise of hub, turning mechanism,
piston, runner blades, bottom cover etc. The loose components may be
runner servo tubes, piston rod, cone and other hardware.
2. Check all the materials as per drg & all tools available for carry out
overhauling.
3. Carry out dismantling, overhauling of partly assembled components,
hydraulic testing of completely assembled runner at site in accordance
with technical requirements, to ensure trouble free operation.
4. Carry out trial lowering of assembled runner in to the runner chamber if
called up before its assembly with shaft to check and ensure clearances
between runner blades and runner chamber with runner blades pulled out.
In the event of clearances being less than those specified in the drawing,
correction is done either by grinding the tip of runner blades / runner
chamber in the complete zone of runner blades operation (i.e. close to
open & open to close).
B. OVERHAULING ASSEMBLY
1.

Runner received in site in dismantled condition, runner blade received
at site separately.

2.

Place runner on pedestal.

3.

Remove bottom cone & perform through checking inside. While
remaining bottom cone ensure match mark is there.

4.

Assemble any loose components & carry out tightening of fastener,
locking called in drg.

5.

Fix bottom cone as per match mark & perform tightening & locking.

6.

Turn the portion of the runner & lower it over the platform made for
runner blade fixing.

7.

Carry out assembly of runner blade with cup seals as per instruction
given in drg.

B. C. ASSEMBLY OF TURBINE SHAFT WITH RUNNER
1.

Place the runner leveled on stools / wooden sleepers.

2.

Check the mating surface of turbine shaft & runner for trueness.

3.

Check & ensure the holes of coupling bolts in runner & shaft and
coupling bolts are as per drg.

4.

Prepare shaft in line with general guidelines and check trueness of all
machined surfaces.

5.

Check and prove bedding of guide bearing pads with guide bearing
journal of shaft, with shaft in horizontal position (Ref. Instructions for
bedding of pads) before runner shaft assy start.

6.

Carry out cleaning, acid pickling, neutralization and oil rinsing interiors
of oil servo tubes. Insert the lower part of servo tube in shaft bore before
runner shaft assy start.

7.

Turn the shaft to make it vertical along with servo tube (runner servo
tube is suspended with chain pulley blocked to the same crane hook
connected to shaft).

8.

Transfer and lower the shaft on to runner. Maintaining accessibility with
shaft suspended, lower and assemble servo tube with piston rod
coinciding match marks and using dowels. Carry out locking of
fasteners and dowels as called for.

9.

Install O-seal, lower the shaft and carry out assembly of shaft with
runner, coinciding the match marks. Install all coupling bolts, tighten to
required stress / elongation as per technical requirement & lock the nut.

10.

Check soundness of runner shaft assembly joint with the help of 0.03
feeler gauge. In the event of correct assembly, feeler gauge will not
pass.

11.

Cover the open end of servo tube temporarily to avoid entry of foreign
materials in to the system.

12.

Prepare FQA log sheet for elongation tightening & completion of runner
shaft assy.

D. HYDRAULIC TESTING OF RUNNER & CHECKING LEAKAGES
1.

If possible, Install PP set, pressure vessel, HP compressors and
commission them / alternately install these equipment’s provisionally for
testing of runner.

2.

Carry out laying and connection of pipes as per the scheme of testing
supplied by the manufacturer.

3.

Carry out testing of runner in the manner stipulated in drawing and
check leakages through sliding mechanisms.

Note : Oil leakage is not permitted, through the cup seals of runner blades.
4.

Testing be continued for the duration as indicated in drawing.

5.

After successful testing, carry out locking of all fasteners as called in
drawing.

Note : Oil leakage is not permitted, through the cup seals of runner blades.
Reference Drg. No.
1) 02040714201

Runner assembly

2) 02050114201

shaft arrangement

3) 02045114201

Tools, tackles & erection device for runner & shaft

4) 02050314201

Arrangement of oil tubes of runner servomotor

5) 02045214201

Testing devices for runner & shaft

log sheets : L-05, L-06
E. INSTALLATION OF RUNNER SHAFT ASSEMBLY
1)

Runner shaft assembly is lowered along with turbine top cover. Runner
shaft assembly is supported on top cover with a suitable supporting
bracket fitted at the seat of turbine guide bearing. Turbine guide bearing
skirt rests over this bracket.

2)

Lower the complete assembly in to runner chamber and carry out
assembly of top cover using seals dowels and fasteners etc. Lower
runner shaft assembly further to make GB skirt rest over the bracket.

3)

Carry out leveling at turbine shaft flange and centering of runner with
runner chamber.

Ref. Drg. No. : 02045114201
Tools, tackles & erection devices for runner & shaft
Log sheet : L-07

C.

PIVOT RING INSTALLATION
1)

Check for the availability of all the materials as per drawing.

2)

Perform visual inspection for any damages. Report to manufacturing unit
if any abnormality is noticed.

3)

Check the matching surfaces of pivot ring for any burr / foreign materials.
Clean, if any.

4)

Ensure availability of proper tools slings etc. for erection of pivot ring.

5)

Check the runner envelop flange level. Grinding to be done if required to
achieve the level.

6)

Lift the pivot ring individual segments and lower them on wooden pegs
kept on the runner envelop / stay ring, for their assembly.

7)

Lift the assembled pivot ring, and lower them over the cleaned resieng
surface.

8)

Tighten the holding down bolts.

9)

Align & level pivot ring as per instructions given in drawing.

10) Lock the bolts as per drawing requirements.
Reference Drgs. : Guide apparatus 02030114201

ASSEMBLY OF OUTER TOP COVER
Outer top cover is in 4 segments. The segments are to be lowered in pit as
individual segments.
1. Clean joint flanges and check for smoothness.
2. Assemble all four segments of outer top cover inside turbine pit.
3. Sling the assembly and lower on speed ring flange as per match mark &
support / hang suitably.
4. Match holes of speed ring flange with that of outer top cover.
5. Put H.D. bolts and tighten.
6. Lock the bolts as per drawing requirement.
Trial assembly to be done by lowering guide vanes using lifting tackles.
During lowering of G.V. the outer top cover may be lifted as per drawing
and position Guide vane assembly. The procedure of Trial assembly is
given in following pages. During final assembly of guide vane also, the
G.V.S. are lowered after lifting Top cover in site using hooks provided in
barrel. Final assembly procedure is also given in following pages.
Check availability as per drg.
 Perform visual inspection report
 Ensure availability of T & Ps.
 Check the leveling of speed ring top flanges and groove area. Grind them
if necessary to achieve drg. Value.
Reference Drg. : Guide apparatus Drg. No. : 02030114201

ERECTION OF GUIDE APPRATUS
PRE-ERECTION CHECKS
1)

Generator barrel is cleared of all civil materials and chipping of stator,
lower bracket foundations completed.

2)

Generator barrel is painted except stator, lower bracket, and upper
bracket foundations.

3)

Turbine pit is cleaned of all civil materials and is painted.

4)

All flanges and threaded holes of stay-ring are cleaned and surfaces
deburred.

5)

Horizontality of stay-ring flanges checked and corrective action executed
wherever required.

6)

All components of guide apparatus and erection devices as per drawing
are received.

TRIAL ASSEMBLY OF GUIDE APPARATUS
1)

Even through the guide apparatus assembly is proved in the
manufacturer’s unit, trial clearances and free turning movements of
guide vanes are as per technical requirements and to establish, lower
ring, top cover positioning and dowelling.

2)

Remove preservatives and clean all the components of guide apparatus
and prepare the components for assembly as per general guidelines.

3)

Depending on type of design, lower ring may be assembled finally with
seals.

4)

Assemble lower ring-using dowels to coincide with XY match marks of
stay-ring.

5)

Centre the pivot ring bent runner envelop

6)

Install all holding down bolts of lower ring and complete tightening.

7)

Lower and position guide vanes as per number match marks.
Note : Thin layer of grease is applied on bearing and guide vane lower
stem before installation.

8)

Assemble four upper guide vane bush housings, 90 degree apart on top
cover. Lift the top cover precisely leveled with the help of turn buckles
and crane and lower it on stay-ring.

9)

Position the top cover using dowels and reference match marks.

10) Install alternate holding down studs of top cover and install all upper
guide vane bush housing (thin layer of grease on guide vane journals
and bush housing before installation).
11) Check and ensure free turning of all guide vanes. While tightening the
nuts of holding down studs till tightening of all nuts of top cover is finally
completed.
12) Bring all guide vanes to close position, to check and ensure the
clearances of guide vanes with top cover at leading and trailing edges
are as per drawing requirements. In case of deviation from the drawing
requirements, corrective action is taken wherever required.
13) Carry out bedding of guide vanes and correction if need be.
14) Lower inner top cover & align it.
15) Complete reaming, doweling of lower ring and inner top cover & outer
top cover.
FINAL ASSEMBLY OF GUIDE APPARATUS
PRE-ASSEMBLY CHECK
1)

Dismantle and remove all the components assembled for trial assembly.

2)

Check the rubber cup seals and O-seals do not carry any cracks and are
not de-shaped.

3)

Install cup seals and retaining rings on lower bush bearing of guide vane

and ensure that retaining ring does not interfere with lower collar of the
guide vane. In case of interference, the retaining ring shall be suitably
machined.
4)

Lower guide vane in position.

5)

Install rubber seal of top cover on stay-ring & complete the assembly of
top cover with stay ring using dowers pins & fasteners ( to ensure proper
assembly of top cover stay ring ,check gap between top cover & stay ring
flange by 0.03 mm feeler gauge ,which should not pass).

6)

Assemble guide vane bush houses with seals and check free turning
movement of each guide vane. (ensure bush house installation with
reference to grease port for pipe connection)

7)

Guide vane should move freely when turned by one person by using
spiral spanner supplied as erection device by the manufacturer. After
installation of bush.

8)

Lower runner assembly with inner top cover runner shaft assembly.
Note : Allowable tolerance in centering 0.1 mm Leveling with 0.03
mm/met.

9)

To facilitate alignment of generator, the runner shaft assembly is installed
in a lower position from designed level by an amount 3-4 mm more than
the spigot height of the generator shaft flange.

10) Check and ensure centering of runner w.r.t. Lower labyrinth on lower ring
is within the specified limits.
11) Install regulating ring and servo motors (refer instructions for installation
of servo motors of different variants, described separately).
12) Install link mechanism and adjust guide vane end clearances, bedding
clearance and clearance between lever and lever stopper / collar.
13) Check free turning movement of all guides vanes from full close to full
open position.
14) Position regulating ring to close of guides apparatus complete centering
and provisional locking.
15) Install connecting rods of servomotors with regulating ring and carry out
pre-stressing of guide apparatus mechanism (refer instructions described
separately).
Note : After final assembly of guide apparatus, grease and lubricate all
bearings and check for easy turning movement of guide apparatus
mechanism by applying oil under pressure in the servo motors. The
complete mechanism should turn freely at oil pressure not more than 5
kg/sq. cm or as indicated in drawing. In case guide apparatus fails to turn
at this pressure, its causes must be investigated and removed.
16) Prepare FQA log-sheet for completion of guide apparatus assembly in
accordance with field quality checks.
PRE STRESSING OF GUIDE APPARATUS MECHANISM

1. Tightness in guide vanes is determined in the following manner upon the
readiness of oil pressure system, governor and completion of working
mechanism in all respects.
2. In closed position of guide vanes, bring the piston of servomotor with
stopper, forward by 15 mm by adjusting the length of connecting rod with
turnbuckle. While doing this, check that regulating ring is not disturbed
and remains in the closed position of guide apparatus.
3. Take the piston of servomotors without stopper, back by same amount i.e.
15 mm in the similar way.
4. Tighten lock nuts of turn buckles of both the connecting rods.
5. Apply oil pressure, according to drawing instructions on servo motor
piston for closing and measure the amount of movement of piston.
Movement of piston so measured is the tightness required in the guide
vanes.
6. Release the oil pressure and install the piston of both the servomotors
from the end support at a distance of tightness value measured.
Complete locking of turn buckles with lock nuts.
7. Apply pressure for closing of guide apparatus and check that.
7.1 The stopper of servomotor moves freely in and out.
7.2 Clearance between adjacent guide vanes all along their height is 00,
when measured with 0.03 mm feeler gauge.
7.3 Guide apparatus servomotor opens to its full stroke, when the oil
pressure is applied for opening of guide apparatus.
8. KINEMATICS OF GUIDE APPARATUS
8.1

Upon completing governor adjustment and readiness of starting the
machine check relationship of guide vanes v/s servomotor and
governor, for opening and closing is as per design requirement (for
Francis turbine)
Check relationship of guide vanes v/s servomotor. Governor and
guide vanes v/s runner blade, governor for closing is as per design
requirement (for Kaplan turbine).

8.2

Plot the graph from the values obtained check that the curve nearly
matches with the design values.

INSTALLATION OF GUIDE VANE SERVO MOTORS
A) Pre-erection checks including overhauling and re-assembly
In case servomotors are not put into service within 12 months from the
date of its dispatch, the same may be over hauled. For this following
procedure may be adopted.
1) Dismantle the servomotor after proper match marking of all

components / joints.
2) Check the cup seal “O” rings of servomotors for any cracks or damage.
Check the interference of cup seals I. D. with sleeve.
3) Clean thoroughly all parts and inside surface of piston and cylinder with
solvents like diesel / petrol check the surfaces of piston, cylinder, piston
rings, bushes etc. for any scratches.
4) Use new cup seals and prepare “O” ring if assembled ones are worn
out and if replacement is necessary.
5) Assemble the covers using “O” ring. Fasten the covers by tightening
the studs and nuts.
6) Insert the piston assembly in the cylinder in vertical position, taking
care to keep the slot portion of piston towards oil ports. Lubricate
cylinder surface profusely with turbine oil as soon as piston rings have
entered the cylinder remove clamp, used for pressing the piston rings.
7) Assemble the cylinder cover using cup seals. Fasten the cover with
stud nut. Locking of nuts to be carried out only after satisfactory
hydraulic testing, & after checking the opening and closing of
servomotor and checking the seals are intact.
B) INSTALLATION
1.

Check and clean the base plates mounted on pit liner. Check
vertically.

2.

Push / pull the servomotor piston fully in/out. Lower servomotor
stopper in position to lock the movement of piston.

3.

Lower both the servomotors in their respective position. Couple
mounting plates with servomotors using studs & nuts.

4.

Align both the servomotors to drg. Dimension. Keep the piston rods of
both servomotors in fully closed position (i.e. piston touching the
respective cylinders ends).

5.

Check the threads of piston rod. If necessary clean and dress with
triangular smooth file.

6.

Level the servomotor precisely (horizontal) check level by precision
block level (accuracy 1 Div = 0.02 mm/m) on piston sleeve level
should be achieved with 1 division.

7.

Assemble the piston rod and connected rod initially, keep 25 mm gap
between piston rod and connecting rod.

8.

The connecting rods of servomotors to be assembled with regulating
ring keeping the guide apparatus fully closed. Also refer the drg. No.
(1) 02030214201, (2) 02030314201, (3) 0203111420 for technical
requirements.

9.

Maintain the distance 1985 of G.V. servo cylinder (Not of piston rods /
connecting rods) and level the servomotor.

10. Now if the gap between mounting plate and plate of pit liner is less
than 3mm weld mounting plates directly to pit liner without using strip,

otherwise they are to be welded using strip as shown in the drawing
no.
11. Check the guide vane bedding its nut as per drg value correct it with
both the servomotor operation.
12. Also check and set if necessary the G. V. servo stroke indicator scale.
TOLERANCE:
1. Center line servomotor is parallel to Y axis and at a distance as specified
in the drawing (within 1 mm).
2. Elevation of servomotor w.r.t. regulating ring (within 1 mm).
Ref. Drg.
02030214201

GV servomotor LH

Log Sheet No.

L-10

02030314201

GV servomotor RH opening of GA depending on

02031114201

Installation of GV servomotor run of GA servomotor
piston

6.0 GUIDE BEARING.
A)
i)

Pre-erection.
Thoroughly clean all parts and joint faces of bearing oil sump. Use
engineers blue on one face, tighten the joint faces and check the
bedding. If necessary scrap the face. Filler gauge can be used to find
out the gap.

ii)

Clean the bearing pads with solvent like petrol and white spirit. Check
their bedding with the bearing journal of the shaft. If necessary
Scrapping can be done. Also check the bedding of Disc. Check that
stud has spherical curvature where it is pressing the disc.

iii)

Measure resistance of RTD with standard mercury Thermometer on
heating as well as on cooling Cycle. Use suitable oils both during
above Calibration.

iv)

Check the groove sizes and prepare rubber-sealing Ring.

v)

Check the working of oil level indicator in Separate oil container out
side.

vi)

Apply liquid sealing compound (hold tight at joint faces of the Bearing
oil sump. Bottom ring)

B) Erection (before alignment)
(i)

Fix. studs called in guide apparatus drg. Assemble bearing housing
with dowel and pins, bolts nuts washer, O-seal respectively, taking care
that no step at any joint.

(ii)

Install the rubber ”o" rings and position the bearing housing matching
with unit axis marked on the top cover and bearing housing.

Center the center piece with respect to turbine shaft journal (with runner at
centre) Tighten nuts and washer.
(iii)

Assemble the pipe assembly in their respective position. Suitably blank
it for testing with kerosene for any leakage through “O” rings. Remove
the kerosene after testing.

(iv)

Fix studs with holdtite. Assemble the two halves of bearing housing,

Match with axis and complete the assembly of bearing housing.
Bearing housing should be checked for any leakage.
(v)

Cover/protect the bearing from dust/foreign material till alignment is
complete.

C. DIRECTION (AFTER ALIGNMENT)
Note: After the unit axis alignment is completed, runner centered with
respect to runner envelop and rotating parts are lying vertical and
locked. Final boxing up of turbine bearing can be taken up.
1. Clean the inside area thoroughly with compressed air/Vacuum cleaner and
moping cloth.
2. Lower the bearing pads and stud and nut in their respective position (i.e.
with respect to RTD & MST connections). Apply molysuff or any other anti
thread seizing grease on the thread of stud. Insert disc and bring stud near
to disc to avoid falling.
3. Install 2 Nos. dial indicators at 90° apart to measure/check the shaft
movement. Set these dial indicators to zero value. Press all the pads so as
to touch the shaft journal.
4. With all bearing pads touching shaft, set the gap of 0.15 to 0.2 between
the disc and stud (Spherical surface) and lock the nut. Re-check the above
clearance.
5. Mount RTD and MST (already calibrated outside).
6. Install bearing cover with all other items as per drawing with "O" seal,
Gasket etc.
7. Assemble bearing oil level controller with its probe.
8. Record all the readings achieved in log sheet.
9. Fill the turbine oil in bearing and centrifuge the oil till it is clear (APPROX)
1 5 TO 20 circulation’s as a guide line
Tolerance: Centering of Bearing Body w.r.t. Shaft with in 0.2 mm.
Ref. drawing: 02060114201

Log sheet L-11

Arrangements of guide bearings

Clearance of Guide Bearing

TURBINE SHAFT SEALING
1. PRE-ERECTION
1.1

Dismantle components of shaft sealing, clean them thoroughly and
check the joint faces for flatness and absence of damage.

1.2

Assemble housing of isolating seal, place the isolating seal and housing
and cut the extra length of seal. Test the isolating seal by air as per
chemical requirements of drawing and confirm expansion of seal under
air pressure.

1.3

Check and grind the top surface of cups, if any projecting over and
above the surface of ring supporting the working seal.

2. ERECTION
2.1

Assemble base plate / housing of isolating seal with top cover along with
“O” seal, maintaining clearances between rotating and stationary parts
as called in drawing (use liquid compound / hold tite at the joints of
housing).

2.2

Install and join isolating seal using suitable adhesive such as anabond /
elfy.

2.3

Place the cover plate in position and assemble it with housing.

2.4

Install cups and lip-type rubber working seal and join it with suitable
adhesive and complete the assembly of cover plate.

2.5

Install upper working seal, join and assemble cover plate.
Note:
i)

Joints of rubber working seal are made taking into account the
direction of rotation of the machine.

ii)

Clearance between rotating and stationary parts is maintained by
grinding wherever necessary.

2.6

Carry out drilling, reaming, doweling of turbine shaft sealing frame with
top cover.

2.7

Connect cooling and pressure water piping

Ref. Drg. No. :

Arrangement of shaft sealing

3. OIL HEADER (REF SKETCH)
3.1

Oil header is intended to supply the oil under pressure from oil pressure
unit to runner servomotor through a set of concentric pipe lines installed
in turbine, generator shafts. The leakage from the runner passes to
pressure pumping set through the bore of turbine, generator shaft and a
oil guide / deflector installed on shaft. Oil pressure for opening closing of
runner blades is supplied through main slide valve of runner installed in
HMC of governor. The runner feed back system & the indicator showing
the position of runner blades are also mounted on the oil header. Oil
header is assembled with runner shaft logged after alignment & center
of runner.

4. PRE ASSEMBLY
4.1 Check individual component of oil header is prepared to technical
instruction.
4.2

Check surface finish of pipe line assembly as per drawing requirement
and there is no ovality on diameter at location where it passes through
the oil header bush.

4.3

Place oil header assembly upside down and ensure the movement of
pipe line assembly, in the oil header bush is smooth.

4.4

Check and record the diameters of bush and pipe line assembly. Check
oil deflector items machined surfaces are true and check level and
surface finish exciter shaft for trueness (where oil deflector is
assembled).

5. ERECTION OF OIL TUBES & OIL HEADER
Following sequence of activities to be followed for erection of oil tubes and oil
header:
5.1

After assembly of runner, shaft and inner top cover in erection bay
check horizontality of the upper flange of oil tube (lower). Upper flange
of oil tube (lower) should be parallel to turbine shaft coupling face.

5.2

Lower the assembly of runner, shaft and inner top cover along with oil
tube (lower) in the turbine pit (preferably after testing of runner on
erection bay).

5.3

Insert middle tube inside generator shaft in erection bay and then lower
in the pit keeping oil tube projected by 200 mm approx. below
generator shaft to facilitate coupling of tubes.

5.4

After connecting middle tube to lower tube and assembly of generator
shaft with turbine shaft, check the horizontality of flange of middle tube
and throw of its spigot.

5.5

Assembly oil tube (upper), check the horizontality of its top flange and
throw of spigot.

5.6

Lower and assemble generator tubular shaft with generator shaft,
check throw of spigot in generator tubular shaft and horizontality of top
flange.

5.7

Lower the assembly of central pipe and pressure box. After assembly
with upper tube, check throw of central pipe and pressure box.

5.8

The allowable value of throw for point no. 4, 5, 6 and pressure box is
preferably 75% of the diametral clearance at pressure box bearing, and
in no case it should exceed the value of diametral clearance.

5.9

The allowable value of throw for central pipe is preferably 75% of the
diametral clearance at central pipe bearing, and in no case it should
exceed the value of diametral clearance.

5.10

If the throw is more than the value mentioned in Para 8 & 9 above,
correction to be done in respective flange face by suitability scraping or
using shims taking care of ‘O’ seal grooves.

5.11

Assembly oil bath and oil guide as per drawing, centralize oil bath to
get the uniform labyrinth clearances.

5.12

Lower oil header body carefully in balanced condition taking guide from
central pipe in such a way that there is no radial pressure or bending
effect on central pipe. If the spigot between body and oil bath does not
match, loosen the spigot suitably by grinding and assembly body to oil

bath.
5.13

After checking free rotation and stroking of oil tubes, dowelling of oil
header body and oil bath to be carried out.

5.14

In extreme position of runner blade stroke (fully open and fully close),
rotate the machine at very slow speed for checking any fouling
between stationary and rotating components.

OIL HEADER AND OIL TUBES
(A) Pre-Erection.
(i)

Check that all items are available.

(ii)

Clean all the components.

(iii)

Prepare all the "0" seals and check for damage/crack, if required
replace it.

GUIDE LINES FOR ERECTION OF OIL TUBES AND OIL HEADER OF
VERTICAL KAPLAN TURBINES
Refer enclosed Sketches No. HTE/SK/001 and HTE/SK/002. Following
sequence of activities to be followed for Erection of oil tubes and oil header.
1.

After assembly of Runner, Shaft and Inner top cover in erection bay
check horizontality of the upper flange of oil tube (lower). Upper flange of
oil tubs (lower) should be parallel to turbine shaft coupling face.

2.

Lower the assembly of Runner, shaft and Inner top cover along with oil
tube (lower) in the turbine pit (Preferably after testing of Runner on
erection bay).

3.

Insert Middle tube inside Generator shaft in erection bay and then lower
in the pit keeping oil tube projected by 200mm approx. below generator
shaft to facilitate coupling of tubes.

4.

After connecting middle tube to lower tube and assembly of generator
shaft with Turbine shaft check the horizontality of top flange of middle

tube and throw of its spigot.
5.

Assemble oil tube (upper), check the horizontality of its top flange and
throw of the spigot.

6.

Lower and assemble generator tubular shaft with Generator shaft, check
throw of spigot in generator tubular shaft and horizontality of top flange.

7.

Lower the assembly of central pipe and pressure box. After assembly
with upper tube, check throw of central pipe and pressure box. .

8.

The allowable value of throw for point no. 4,5,6 and pressure box is
preferably 75%. of the diametral clearance at pressure bob bearing , and
in no case it should exceed the value of diametral clearance.

9.

The allowable, value of throw for central pipe is preferably 75%. of the
diametral clearance at central pipe bearing, and in no case it should
exceed the value diametral clearances.

10.

If the throw is more than the value mentioned in Para 8 & 9 above,
correction to be done in Respective flange face by suitably scraping or
using shims taking care of "O” seal grooves.

11.

Assemble oil bath and oil guide as per drawing, centralize oil bath to get
the uniform labyrinth clearances.

12.

Lower oil header body carefully in balanced condition taking guide from
central pipe in such a way that there is no radial pressure or bending
effect on central pipe. If the spigot between body and oil bath does not
match, loosen the spigot suitably by grinding and assemble body to oil
bath. Grinding can be carried out since there are 4 Dowels of 16mm in
addition to 16 studs of nuts of M20 for holding the body with oil bath
which keep the joint tight even in running condition job the Machine.

13.

After checking free rotation and stroking of oil tubes, dowelling of oil
header body and oil bath to be carried out.

14.

In extreme positions of Runner blade stroke (fully open and fully close),
rotate the machine at very slow speed for checking any fouling between
stationary and rotating components.

15.

CHANGES DUE TO REVISION: NIL

16.

ENCLOSURES: Sketch No. HTE/SK/001 & HTE/SK/002

Tolerance: 1. Centering of oil Header - within 0.1 mm
2. Centering of Center tube - within 0.15 (By rotational check).

GOVERNING EQUIPMENT
(i)

Pressure pumping set.

(ii)

Pressure Receiver.

(iii)

Hydro mechanical cabinet & runner control mechanism.

(iv)

Feed back mechanism.

Pressure Pumping set
(A) Pre - erection
(i)

Check all the pockets of foundation are as per drawing. Ensure sides of
these pockets are slightly rough for proper bondage of concrete.

(ii)

Chip the concrete to make it supporting surface level, if necessary.

(iii)

Check that all the blanking flanges are intact.

(B) Erection.
(i)

Lift the complete P.P. Set assembly on 4 equal wire Ropes, using eye
bolts in fairly levelled condition

(ii)

Install the P.P. Set as per drawing dimensions. Check the elevation at 4
places. Ensure no gap exists between supporting brackets and
concrete.

(iii)

Check the vertically by plum bob at pipe flanges.

(iv)

Fill the pockets by concrete and allow it to cure.

(v)

Check that motor is free, bearing is sound. Grease the bearings.

(vi)

Do not run the motor with out oil in the tank.

(ii) Pressure Receiver
(A) Pre-Erection .
(i)

Check that foundation pockets are as per drawing.

(ii)

Remove manhole door and inspect for any rusting from inside surface
or foreign material during Transportation. Check the paint condition
from inside.
Place the manhole door in the position if required replace the gasket.

(iii)

(B) Erection.
Lift the pressure receiver in balance condition and assemble it on the

(i)

foundation bolts. Align the pressure receiver as per drawing dimension.
Care to be taken that angular position of the mountings are as per
drawing.
(ii)

Check the verticality by pump bob on two planes.

(iii)

Mount all the fittings on receiver and prevent them from any damage
(Glass parts/pressure gauges).
Pressure test the receiver with air and check leakage through any

(iv)

fittings.
Hydro Mechanical Cabinet & Runner Control Mechanism
(A) Pre-erection.
(i)

Check all the items for any damage/breakage.

(ii)

Clean the component cleanly.

(iii)

Check the location and size of the pockets are as per drawing
dimension.

(B) Erection.
(i)

Install the hydro mechanical and electrical cabinet as per the drawing.

(ii)

Use leveling screws to leveling screws to level and achieve elevation
as per drawing.

(iii)

Check the verticality of the cabinets by plum bob and also check level,

with precision level, of the rod for free movement of kinematics.
Note :After installation of above panels dust/ moisture in this area should not be
allowed. As such, all precautions like chipping/cleaning in the surrounding are
to be taken prior to installation of these cabinets.
 Arrangement of PP set

-

02210114201

 Arrangement of pr. Receiver

-

02200114201

 Hydro mechanical cabinet

-

02085014101

 Runner control mechanism

-

02083614101

Installation of feed back System
(i)

Check that all items are available and are in sound condition.

(ii)

Wire rope be pre-stressed to 300 kg. . Force, for 24 hrs. before
installation or as called in drg.
Wire rope joint to be made as suggested in technical requirement of

(iii)

the drawing.
Touching of wire rope with any bracket, tube etc. is not allowed.

(iv)

Movement of wire rope should be free.
(v)

All bearings be lubricated and wire rope greased before use.

(vi)

Kinks and broken stands in wire rope greased before use.

(vii)

Wire rope after installation should be in tension (not loose, to avoid any
back lash)

(viii)

Sharp bends of wire rope to be avoided.

Ref . : Drg. : Feedback mechanism – 0208-48-14201

METERING AND INSTRUMENTS AND SHEAR PIN CONTACTS
A) METERING INSTRUMENTS
i)

Calibrate pr. Gauge, DTTT’s, RTDs, etc. called in drg.

ii)

Install metering instrument panel and assemble all instruments as per
layout drawing. Carryout laying, welding of pipes and install supports,
clamping etc.

iii)

Dismantle pipes, complete cleaning by blowing air at 5-7 Kg atm.

iv)

Install all pipes and clamping arrangements with supports.

v)

Install pressure gauges on draft tube cone, penstock, spiral case and
other instruments as per layout drawing.
Note :
1. Carry out hydraulic testing of pipelines wherever called for.
2. Ensure calibration of all metering instruments prior to putting them
in service.

B) SHEAR PIN CONTACTS
i)

Shear pin is a weak link between strap and guide vane lever and
fails in the event of blocking or jamming of guide vanes. With the
failure of shear pin guide vane becomes free of its turning
movement and strap alone moves and opens the contacts of the
limit switch to initiate a warning signal of shear pin failure at UCB.
The limit switches are connected in series with normally closed
contact.

C) ERECTION
i)

Install all base plates of unit switches, strikers and clamps as per
layout details.

ii)

Assemble limit switches and strikers with their respective base
plates such that the limit switch remains pressed with striker and
the contacts are closed.

iii)

Carryout laying, clamping and connecting of cables with guide
apparatus open, providing a little additional allowances in the cable
for flexibility.

iv)

Complete sealing of glands to ensure water tightness.
 Installation of metering instruments – 12100314201

 Guide apparatus

METERING AND INSTRUMENT PANEL
1. Calibrate the Pressure Gauge.
2. Calibrate DTT'S and RTDS
3. Mount the Pr. Gauges, DTT'S and RTDS as per the scheme.
4. Check and connect the pipe lines as per the technical requirement given
in the drawing and document supplied separately by BHEL Bhopal.
5. Wiring of the equipment to be done as per the scheme.
6. Calibration of ammeter, Voltmeter, Wattmeter to be done.
Ref.: Drg. No.

AUXILIARIES
1

Cooling water system

2

Compressed air system

3

Drainage & Dewatering system

4

Pipes in Turbine Pit

5

Turbine gauge panel piping

6

Turbine pit platform

7

Monorail in Turbines Pit

8

Arrangement of top Cover Drain pipes

9

Turbine rating Plates

Note: For erection of all the above Equipment refer the respective drawing &
documents of the equipment. PP Set, HMC, RCM, Pr. Receiver.

ALMATTI HEP
TURBINE DRAWINGS – 55 MW
UP DATED AS ON – 14/06/2004
Sl. No

Drg. Title

Drg. No.

Rev. No. of Remarks
No. Sheets

T1

STATION LAYOUT

0-200-00-14201 03

03

T2

INSTALLATION OF PIER NOSE 0-201-03-14201 01
LINER

01

T3

PIPING & EMBEDMENTS IN 1ST 0-201-04-14201 01
STAGE

02

T4

INSTALLATION OF D. T. LINER 0-201-02-14201 01

02

T5

DRAFT TUBE WATER PATH

1-201-00-65602 01

01

T6

EXTENDED DRAFT TUBE
LINER BEYOND PIER NOSE

KPCL/ADPH/DT
L/55-01

02

T7

EXTENDED PORTION DT
KPCL/ADPH/DT
LINER (5 X 55 MW) SUPPORT L/15-04
STRUCTURE ARRANGEMENT

01

T8

EMBEDDED TUBES FOR
FIELD EFFICIENCY TEST

0-201-11-14201 02

01

T9

INSTALLATION OF D.T. CONE 0-201-01-14201 02

01

T10

EMBEDMENTS & PIPES IN
SECOND STAGE

0-202-08-14201 02

03

T11

DETAILS OF PIERS

0-202-08-14203 00

01

T12

DRAINAGE & DEWATERING
SYSTEM

0-211-01-14201 00

01

T13

DETAILS OF PIERS

0-202-09-14201 01

02

T14

STAY RING HALVES

02-02-01-14201 00

02

T15

STAY RING INSTALLATION

0-202-01-14201 01

02

T16

SPIRAL CASING

0-202-02-14202 00

03

T17

PARTITION PLATES

1-202-02-14201 00

01

T18

Installation of spiral casing

0-202-02-14201 02

03

T19

Arrangement of spiral testing

0-202-52-14201 01

01

CHECK

T20

INSTALLATION OF INLET PIPE 0-202-04-14201 01
TO SPIRAL CASING

01

T21

RUNNER ENVELOPE
INSTALLATION

0-202-06-14201 00

02

T22

INSTALLATION OF PIT LINER

0-202-07-14201 01

02

T23

TOOLS TACKLES & ERECTION 0-203-51-14201 02
DEVICES OF GUIDE
APPARATUS

02

T24

ARRANGEMENT OF RUNNER 0-201-51-14201 01
INSPECTION PLATFORM

01

T25

MONORIAL IN TURBINE PIT

0-210-09-14201 00

01

T26

GUIDE APPARATUS

0-203-01-14201 01

01

T27

TOOLS TACKLES AND
ERECTION DEVICES FOR
RUNNER AND SHAFT

0-204-51-14201 00

03

T28

RUNNER ASSEMBLY

0-204-07-14201 01

03

T29

SHAFT ARRANGEMENT

0-205-01-14201 00

01

T30

ARRANGEMENTS OF OIL
TUBES OF RUNNER
SERVOMOTOR

0-205-03-14201 00

02

T31

TESTING DEVICES FOR
RUNNER & SHAFT

0-204-52-14201 00

01

T32

INSTALLATION OF G. V.
SERVOMOTOR

0-203-11-14201 00

01

T33

G. V. SERVOMOTOR L.H

0-203-02-14201 01

02

T 34

G. V. SERVOMOTOR R.H

0-203-03-14201 01

02

T35

ARRANGEMENT OF P.P. SET

0-221-01-14201 02

01

T36

ARRANGEMENT OF
PRESSURE RECEIVER

0-220-01-14201 03

01

T37

HYDRO MECHANICAL
CABINET

0-208-50-14101 00

01

Check

T38

RUNNER CONTROL

0-208-36-14101 00

02

MECHANISM

T39

OIL PIPE LINES

0-210-18-14201 00

03

T40

FEED BACK MECHANISM

0-208-48-14201 00

02

T41

COOLING WATER SYSTEM

0-299-20-14201 00

03

T42

250NB RUNNER AERATION
VALVE

T43

PIPE IN TURBINE PIT

0-210-17-14201 00

02

T44

INSTALLATION OF
FLOWMETER EQUIPMENTS
AND ITS PIPING

1-210-16-14201 00

01

T44

OIL HEADER

0-205-02-14201 00

02

T46

INSTALLATION OF METER ING 1-210-03-14201 01
EQUIPMENTS

01

T47

ARRANGEMENT OF GUIDE
BEARING

02

T48

ARRGT OF SHAFT SEALING

T49

INSTALLATION OF RAILING
AND PLATFORM IN TURBINE
PIT

0-210-11-14201 01

02

T50

TOOLS TACKLES AND
ERECTION DEVICES WITH
INSTALLATION OF SPANNER
BOARD

0-210-51-14201 00

01

NA

0-206-01-14201 00

NA

ANNEXURE
LOG SHEETS
Description

Log Sheet No

Installation of Draft Tube knee Liner

L-01

Installation Of Stay Ring

L-02

Installation of Stay ring & Spiral Casing

L-03

Installation of runner chamber

L-04

Test Certificate for Kaplan Runner Assembly

L-05

Elongation of Fitted Bolts between Runner & Shafts

L-06

Clearance between Runner and Shaft

L-07

Clearance of Guide Vane

L-08

Clearance of Guide Vane

L-09

Opening of Guide Apparatus depending upon the
run of G.A. Servomotor Piston

L-10.

Clarence of Guide Bearing

L-11

Elongation of Fitted Bolts between Turbine Shaft
& Generation Shaft

L-12

Centering of Unit axis

L-13

Runner Blade Opening v/s Guide Apparatus opening L-14
Observation of measurements during Spinning
& Loading (2 sheets)

L-15

Page No.