Presentation of Turbine Erection 1

MHI Turbine Generators

SUMMER TRAINING AT 2X700 MW RAJPURA THERMAL POWER

PLANT, PUNJABBy- Anubhav Singhal, NPTI (New Delhi)

LARSEN & TOUBRO LARSEN & TOUBRO


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


TURBINE ERECTION FLOW CHART 　STEP-1 STEP-1

Centering Of Centering Of Turbine FoundationTurbine Foundation

STEP-2 STEP-2 Setting of levelling Plates Setting of levelling Plates

and Levelling Wedgesand Levelling Wedges

STEP-3 STEP-3 Setting of Turbine Setting of Turbine

seatingPlates seatingPlates

STEP-4STEP-4Installation of LP Installation of LP

Outer casingOuter casing

STEP-4STEP-4Installation of LP Installation of LP

Outer casingOuter casing

STEP-5 STEP-5 Installation of HIP Installation of HIP Module and HP/IP Module and HP/IP

PedestalPedestal

STEP-5 STEP-5 Installation of HIP Installation of HIP Module and HP/IP Module and HP/IP

PedestalPedestal

STEP-6STEP-6Levelling & centering

Of LP-1 and LP-2Casing

STEP-6STEP-6Levelling & centering

Of LP-1 and LP-2Casing

STEP-7STEP-7Install bearings Install bearings

and Rotorsand Rotors

STEP-7STEP-7Install bearings Install bearings

and Rotorsand Rotors

STEP-8STEP-8Provisional centering

Of LP-1 & LP-2

STEP-8STEP-8Provisional centering

Of LP-1 & LP-2

STEP-9STEP-9Provisional centering of Provisional centering of

HIP & LP 1 RotorHIP & LP 1 Rotor

STEP-9STEP-9Provisional centering of Provisional centering of

HIP & LP 1 RotorHIP & LP 1 Rotor

STEP-10STEP-10Installation of innerParts of LP casing

(Pre Assembly)

STEP-10STEP-10Installation of innerParts of LP casing

(Pre Assembly)

STEP-11STEP-1122ndnd centering of HIP centering of HIP

Turbine –LP TurbineTurbine –LP Turbine

STEP-11STEP-1122ndnd centering of HIP centering of HIP

Turbine –LP TurbineTurbine –LP Turbine

STEP-12 STEP-12 Final AssemblyFinal Assembly

STEP-12 STEP-12 Final AssemblyFinal Assembly

STEP-15STEP-15Oil FlushingOil Flushing

STEP-13 STEP-13 GroutingGrouting

STEP-14STEP-14Checking Final Checking Final

Coupling alignment Coupling alignment And couplingAnd coupling

STEP-16 STEP-16 Final assembly of Final assembly of

Pedestal Turning gearPedestal Turning gear& others& others


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.



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”.


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.


SETTING OF TURBINE SEATING PLATES

Seating plate

Adjusting bolt


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 G-n.


INSTALLATION OF LP LOWER OUTER CASING

Guide Pillar


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 G-n.

• Prior to installing the HIP module, both side of the centering beam shall be fitted to LP-1 pedestal and HP pedestal temporary.


3D VIEW OF HIP PEDESTAL SEATING PLATE & HIP PEDESTAL


HIP Extension Shaft

HIP Pedestal

HIP Extension Shaft

Guide Pillar for HIP Module


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.


Levelling of HIP Pedestal by optical scope

HIP Pedestal Seating plate

Leveling Wedge


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


INSTALL LP ROTOR


Contact check

Blue paste apply on Journal

Journal

Bearing

Guide Pillar

Bearing Bottom surface

Jacking Oil Inlet


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.


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.


ALIGNMENT OF LP-2~LP-1 TURBINE ROTOR

LP 1 Rotor


BEARING ALIGNMENT CURVE


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.


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.

Radial Pin


Install Inner casing carefully.Install Steam chamber

Install Blade Ring Install Sp. Stationary Blade


Install Flow Guide


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.


INSTALL LEAD WIRE ON ROTOR AND INNER CASING

Instal Lead wire


Reamar bolt tightning

Lifting of inner casing Lead Wire remove


HIP INTERNALS

Thermal Shield (IP)

IP Blade Ring

Dummy Ring #1 (MS) HP INNER CASING


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.

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.


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.

Adjusting Liner settingAdjusting Liner setting Adjusting Liner MachiningAdjusting Liner Machining


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


Inner casing Install

Bolt Tightning


Outer casing

Flow Guide inside OC Outer Casing installation


Step 12

Guide PillarLevel Checking

Bolt Tightning


Guide PillarLevel Checking

Bolt Tightning


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.


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=LP-2=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.


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.


Documents

Presentation of Turbine Erection 1