SUMMER TRAINING AT 2X700 MW
RAJPURA THERMAL POWER
PLANT, PUNJAB
By- Anubhav Singhal, NPTI (New Delhi)
MHI Turbine Generators
INTRODUCTION
• TRAINING TOPIC
: TURBINE ERECTION
• TRAINING LOCATION : 2X700 MW RAJPURA THERMAL POWER
PLANT, PUNJAB
• TRAINING DURATION : 20.06.2013 TO 10.08.2013
• TRAINER
: MR. DEEPAK GOYAL
(TURBINE ERECTION – MECHANICAL)
LARSEN & TOUBRO
It’s all about Imagineering
MHI Turbine Generators
TURBINE ERECTION FLOW CHART
STEP-1
Centering Of
Turbine Foundation
STEP-2
Setting of levelling Plates
and Levelling Wedges
STEP-3
Setting of Turbine
seatingPlates
STEP-4
STEP-4
Installation
InstallationofofLP
LP
Outer
casing
Outer casing
STEP-5
STEP-5
Installation
InstallationofofHIP
HIP
Module
Moduleand
andHP/IP
HP/IP
Pedestal
Pedestal
STEP-6
STEP-6
Levelling
Levelling&¢ering
centering
Of
LP-1
and
Of LP-1 andLP-2
LP-2
Casing
Casing
STEP-7
STEP-7
Install
Installbearings
bearings
and
andRotors
Rotors
STEP-12
STEP-12
Final
FinalAssembly
Assembly
STEP-8
STEP-8
Provisional
Provisionalcentering
centering
Of
OfLP-1
LP-1&&LP-2
LP-2
STEP-13
Grouting
STEP-9
STEP-9
Provisional
Provisionalcentering
centeringofof
HIP
HIP&&LP
LP 11Rotor
Rotor
STEP-14
Checking Final
Coupling alignment
And coupling
STEP-10
STEP-10
Installation
Installationofofinner
inner
Parts
of
LP
casing
Parts of LP casing
(Pre
(PreAssembly)
Assembly)
STEP-15
Oil Flushing
STEP-11
STEP-11
ndnd
22 centering
centeringofof HIP
HIP
Turbine
–LP
Turbine
Turbine –LP Turbine
STEP-16
Final assembly of
Pedestal Turning gear
& others
MHI Turbine Generators
CENTERING OF TURBINE FOUNDATION
• The basic centerline of the turbine and generator
foundation shall be confirmed according to the
foundation drawing.
• The position of foundation bolts and anchor blocks
from the centerline of turbine shall be confirmed and
recorded.
• The basic centerline of turbine shall be check by
optical scope.
• Optical scope shall be on referance elevation mark.
• Top surface of the foundation shall be chipped.
MHI Turbine Generators
MHI Turbine Generators
SETTING OF LEVELLING PLATES & LEVELLING
WEDGES
• Leveling plates and leveling wedges shall be fixed
by grouting to their correct position with a level
wedge shall be consider with “Rotor alignment
curve”.
MHI Turbine Generators
SETTING OF TURBINE SEATING PLATES
• Before setting of seating plate, contact should be cleaned and
each seating plate shall be located and be set on its correct
position.
• Adjusting bolts shall be installed on the seating plate with
thread paste.
• After seating plates in place, a piano wire shall be stretched on
between the centerline of the turbine, then accurate centering
of each seating plate shall be made according to this piano
wire. Tolerance shall be not more than +/-2mm from centerline.
• Elevation tolerance : 0~ -0.5 mm
• Each seating plate shall be adjusting bolts and leveling
wedges. To measure the height of the seating plate to surface,
using straight-edge with level vial. Permissible tolerance is
within 0.25MM/M.
MHI Turbine Generators
SETTING OF TURBINE SEATING
PLATES
Adjusting bolt
Seating plate
MHI Turbine Generators
INSTALLATION OF LP LOWER OUTER
CASING
• The machined surface of seating plate , machined
contact lower surface of horizontal joint and vertical
joint shall be cleaned before installation of LP
turbine. And checked to find damage such as
scratch. And if scratches are found surface shall be
smoothed up by oil stone before installation.
• Surface of seating plates shall be thinly coated with
anti-seazing compound is equivalent to Molykote Gn.
MHI Turbine Generators
INSTALLATION OF LP LOWER OUTER
CASING
Guide Pillar
MHI Turbine Generators
INSTALLATION OF HP PEDESTAL & HIP MODULE
• The machined surface of seating plate , machined
contact lower surface of horizontal joint and vertical
joint shall be cleaned before installation of HIP
Pedestal. And checked to find damage such as
scratch. And if scratches are found surface shall be
smoothed up by oil stone before installation.
• Surface of seating plates shall be thinly coated with
anti-seazing compound is equivalent to Molykote Gn.
• Prior to installing the HIP module, both side of the
centering beam shall be fitted to LP-1 pedestal and
HP pedestal temporary.
MHI Turbine Generators
3D VIEW OF HIP PEDESTAL SEATING PLATE
& HIP PEDESTAL
MHI Turbine Generators
HIP Extension Shaft
HIP Extension Shaft
HIP Pedestal
Guide Pillar for HIP Module
MHI Turbine Generators
LEVELLING & CENTERING OF HIP, LP1 AND LP2
CASING
• Lower casing shall be adjusted to level and elevation at
the horizontal joint using automatic/ level edge with level
vial. Adjustment shall be performed using jacking bolts,
levelling wedge and shim liner of seating plate. Then the
target level of horizontal joint of LP casing shal be with
0.25mm/m.
• Piano wire shall be re-set the centerline of turbine
generator. Each casing center (LP-2 casing,LP-1 casing)
shall be aligned and installed with scale within 1 mm
target to piano wire as standard line by moving casing
and seating plate together.
• Finally, relative location of each part (HP pedestal, HIP
casing,LP-1 casing, LP-2 casing) should be measured the
distance from center line of each parts.
MHI Turbine Generators
HIP Pedestal
Seating plate
Leveling Wedge
Levelling of HIP Pedestal by
optical scope
MHI Turbine Generators
INSTALL BEARING
• Prior to installation of rotor No 1 and No 2 bearings shall
be installed, and each bearing (No. 3. No. 4, No.5, No.6)
shall be installed with sperical key. And each bearing
shall be conformed contact mark with Blue check paint
so that there is more than 75% contact.
Bearing
MHI Turbine Generators
INSTALL LP ROTOR
MHI Turbine Generators
Journal
Bearing Bottom
surface
Guide Pillar
Bearing
Jacking Oil Inlet
Contact check
Blue paste apply on
Journal
MHI Turbine Generators
PROVISIONAL CENTERING OF LP2 TO LP1 ROTOR
• This alignment work shall be started from LP-2 turbine rotor
level, because LP-2 Turbine is axial center and zero base of this
train.
• Each rotor has to be aligned at same time according to
elevation.
• It is described that centering work of LP-2 ~LP-1 .
• Measure LP-2 rotor level on top of No.5 and No. 6 bearing
journal.
• And rotor level shall be adjusted by seating plate for pedestal
utilizing jacking bolt, levelling wedge and/or shim liner, if
necessary.
MHI Turbine Generators
PROVISIONAL CENTERING OF LP 1 to HIP TURBINE
• Measure LP-1 rotor level on top of No.3 and No.4 bearing
journal.
• And rotor level shall be adjusted by seating plate for
pedestal utilizing jacking bolt,leveling wedge and/or shim
liner, if necessary.
MHI Turbine Generators
ALIGNMENT OF LP-2~LP-1 TURBINE ROTOR
LP 1 Rotor
MHI Turbine Generators
BEARING ALIGNMENT CURVE
MHI Turbine Generators
INSTALLATION INNER PARTS OF LP TURBINE
(PRE-ASSEMBLY)
• Prior to install inner parts, it’s shall be cleaned by
solvent such as kerosene to remove anti-corrosion
coat. Also machined surface shall be conformed
smooth by oilstone. Finally, nerrow areas of inner
parts such as bolt hole, keyhole,groove and drain
hole shall be cleaned by air blow.
• Before lifting Inner casing check sealing, D cycle,
and chain block it should not damage. Use two
sealing and Two chain block for lifting Inner casing.
• Check Its radial key it should be properly welded.
MHI Turbine Generators
Radial Pin
Check Its radial key it should
be properly welded
Lift the inner lower casing and check
level it should be equal in four
machine corner if not equal then make
equal by chain block.
MHI Turbine Generators
Install Inner casing carefully.
Install Blade Ring
Install Steam chamber
Install Sp. Stationary Blade
MHI Turbine Generators
Install Flow Guide
MHI Turbine Generators
RECORD OF CLEARANCE
• Prior to install LP-1, LP-2 rotors, lead wire shall be put on
each stage labyrinth fin to measure clearance.
• LP 1 and LP 2 Rotor shall be installed.
• Radial clearance (Right & left) & Axial clearance
measured by taper guage and Fillar guage.
• Install Upper inner casings to measure upper labyrinth
clearance.
• Tighten casing bolt to fit upper and lower casing.
• upper inner casings and rotors shall be taken out from
the casing. Lead wire shall be taken out for measurement.
• Each clearance shall be considered about “Rotor and
casing deflection”.
• LP-1 and LP-2 Rotor shall be installed again.
• Amount of rotor movement from K position and total float
of each rotor shall be measured and recorded.
MHI Turbine Generators
INSTALL LEAD WIRE ON ROTOR AND INNER CASING
Instal Lead wire
MHI Turbine Generators
Reamar bolt tightning
Lifting of inner casing
Lead Wire remove
MHI Turbine Generators
HIP INTERNALS
Thermal Shield (IP)
IP Blade Ring
Dummy Ring #1 (MS)
HP INNER CASING
MHI Turbine Generators
2nd CENTERING OF TURBINE
• The centering of LP 2 turbine and LP 1 turbine shall be carried
out by movement of LP-1 rotor.
• The centering of LP 1 turbine and HIP turbine shall be carried
out by movement of HIP rotor.
• The centering of LP 2 turbine and generator shall be carried out
by movement of the generator rotor.
• Zero points marked on the each rotor shall be turned through
180 degree and placed at the bottom and the clearance
between the matching coupling faces measured.
MHI
Turbine
Generators
Alignment
of LP 2~
LP 1
SETTING OF THE ADJUSTING LINER & BUSH FOR
TIE BEAM
• The clearance between Tie beam and casing will be checked
and recorded.
• After insert of the pin for Tie beam, the bush shall be machined
to its regular thickness at the site and shall be set. After
setting, the bush shall be tack welded to lock.
MHI Turbine Generators
SEATING OF THE ADJUSTING LINER FOR ANCHOR
BLOCKS
• Before setting of the adjusting liner for anchor block, the
inclination of surface of anchor blocks shall be conformed.
• ( Tolerance of inclination of surface +/- 1.5mm )
• After confirmation of the inclination of anchor blocks. The
adjusting liners for anchor blocks shall be machined to its
regular thickness at site.
FINAL ASSEMBLY
• After completion of the measurements and verification of
clearance, final assembly shall be commenced. Each parts
shall be cleaned by compressed air prior to the final assembly.
• All Inner casing stud bolt will be tightned by Hot Tightning.
Blade ring Install
Steam chamber Install
MHI Turbine Generators
Inner casing Install
Bolt Tightning
MHI Turbine Generators
Outer casing
Flow Guide inside OC
Outer Casing installation
MHI Turbine Generators
Step 12
Level Checking
Guide Pillar
Bolt Tightning
MHI Turbine Generators
Level Checking
Guide Pillar
Bolt Tightning
MHI Turbine Generators
GROUTING
• After completion of 2nd centering of turbine and
generator the grouting stopper shall be installed
around the turbine casing, pedestal and generator.
• Grouting shall be carried out when the tubine has
been assembled and is loaded with almost all related
weightupon it.
• Cleaned the places to be grouted by blowing air and
washing with water.
• Fill the clerance between foundation bolt and
sleeves with grout just before grouting.
MHI Turbine Generators
CHECKING OF FINAL COUPLING ALIGNMENT
AND COUPLINGS
After completion of installing the turbine, couplings of the
turbine to generator shall be checked for HIP=LP-1=LP2=GEN alignment and be readjusted if necessary.
Coupling reamer bolts shall be installed Tightened and
controlled by streatched length of bolts,Tightened value of
coupling reamer bolts
– HIP ~ LP-1 Coupling Bolts = 0.375 ~ 0.431mm
– LP-1 ~ LP-2 Coupling Bolts = 0.432~ 0.497mm
– LP-2 ~ GEN Coupling Bolts = 0.623 ~ 0.717mm
Thrust bearing assembly and clearance check.
MHI Turbine Generators
OIL FLUSHING, FINAL ASSEMBLY OF
PEDESTAL, TURNING GEAR, COUPLING
GUARD AND OTHERS
•
•
•
•
•
Oil Pipping Flushing
The purpose of oil flushing prior to operation of turbine
generator is to flush from oil system of foreign material
wich instruded in the system during the installation stage.
After completion of Oil flushing, Top half of each Journal
bearing and thrust bearing shall be installed finally.
Turbine supervisiory equipment (differential expansion pick up,
vibration pick up, essentricity pick up, speed pick up, etc) and
other accessories shall be installed finally.
Coupling Guard (HIP,LP-1/LP-2,GEN) shall be set.
Bearing cover and pedestal cover shall be installed.
Turning device shall be set according to the designed back
lash & tooth contact obtained and set dowel pin.