STEAM TURBINE

500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
1. ASSEMBLY OF BEARING AT SITE
1.1. GENERAL DESCRIPTION
The KWU design machine are supplied with four bearings out of which three
are the journal bearing and one is combined thrust and journal bearing on H.P.
rear end of the shaft. All the turbine bearing are self aligning type and they
adjust themselves as per the catenary of the machine.
The function of a journal bearing is to support the turbine shaft but the
thrust bearing support the shaft as well as wor! as a fi" point for the turbine
shaft. The contact arrangements between bearing and bearing supports are of
two types i.e. sphere to sphere in HP front and HP rear bearing and torus to
cylindrical in other bearings.
The bearings are supplied to site after ensuring their contact at wor!s. #uring
erection all the bearing are supplied to site in aligned and assemble condition
in their individual pedestal from the wor!s. After alignment of the bearing in
their pedestal the seat of the bearing are doweled before dispatch to site.
$n case of Thrust and %ournal bearing the seat of the bearing neither doweled
from the wor!s nor it is recommended to be doweled at site. The bearings
need preparation before placement of module in position at site. This can be
done even before the placement of pedestal in position for grouting.
1.2. ASSEMBLY PROCEDURE
&.'.&. After opening the pedestal remove and clean the bearing including its spherical(
cylindrical seat.
&.'.'. )emove oil guard ring and its duct and !eep them in proper place for their
storage at site.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
&.'.5. Handle bearing carefully to avoid any damage to the babbit and its
torus(spherical piece. #uring storage at site avoid direct loading of bearing on
its torus. A thic! rubber seat may be used during handling of bearing at site
on its torus.
&.'.4. +nsure -.-5 feeler tightness on bearing parting plane. $n case of any
variation the matter may be referred to designers.
&.'.6. 7easure bore dia of the bearing and journal dia at site and ensure the oil
clearances. $f any discrepancy is observed designer may be referred.
&.'.8. +nsure torus(spherical contact with their seats at site. While chec!ing the
contact the seat may be bolted with their pedestal. $n case variation contact
from their specified diagrams are noticed then following may be carried out at
site9/
$n case of torus to cylindrical seats the line contact are recommended by
designers. $f these lines are not straight and are in angle then the
bearing may be rejected straight way and sent to wor!s for rectification. These
line contact may be in a width of about '- mm throughout on its seat leaving
with area on both sides. The contact may be wide in :enter and then
gradually reducing on sides. $n case there is no contact is achieved in the
center and only sides are having contact then a feeler gap may be recorded
in bottom. $n case if the bottom is tight to a feeler of -.-5 mm the bearing
may be accepted at site without doing any rectification.
$n a reverse case the contact are achieved in center only though the -.-5
feeler is not going in the side. The bearing may be still accepted at site. $n
case if the feeler is going in the bottom or in sides by -.-5 mm. the bearing are
not accepted at site and can be sent bac! for the rectification to the wor!s.
;imilarly if the contact are intermittent on its seat but in a straight line and
no feeler is going the bearing may be accepted. $n case of very wide contact
also the bearing may be sent bac! for the rectification. While chec!ing these
contact very light color may be put on torus of the bearing. *efore sending bac!
the bearing to the wor!s the matter may be referred to designers and their
concurrence is to be obtained. 3o scrapping(lapping is recommended in
these bearing for improvement of the contact.
$n case of spherical to spherical bearing the contacts are called in the center
li!e a moon shape. $n these bearings even full contact may be accepted.
*ut in case if there are contact on sides and a feeler gap is noticed on center
then the bearing may not be accepted.
$n such cases if the gap is upto -.-5 mm then the
matching(lapping may be carried out at site. *ut in case of higher
gap the matter may be referred to designers. $n case of reverse
case if the feeler gap of -.-5 is noticed on both sides of the
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
bearing the bearing may not accepted at site and matter may be
referred to designers.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
&.'... *efore chec!ing the contact between torus and its seat ensure that the seat is
feeler tight to -.-5 mm without tightening of any bolts with the pedestal. $f
necessary this may be corrected with consultation of designers. ;imilarly
ensure contact between torus< spherical piece with bearing and in case of
variation the matter be referred to designers and no correction is to be carried
out at site without the approval of manufacturing unit.
&.'.1. *efore chec!ing the contact between torus(spherical piece with bearing and in
case of variation the matter may be referred to designers and no correction
is to be carried out at site without their recommendations.
&.'.0. The si=es of all the shims may be punched in bearing body and spherical(torus
piece of the bearing. The number of shims are to be limited to 5/4 numbers
only even after complete alignment of machine. A protocol for number of shims
may be prepared.
&.'.&-. Torus(spherical should not have any radial movement over its bearing.
This can be seen after opening the torus from the bearing.
&.'.&&. :hec! jac!ing oil lines of the bearing and clean them thoroughly.
+nsure jac!ing oil lines fittings also for their male female threads etc
otherwise this may create the oil lea!age through these lines during operation
of the machine. The jac!ing oil poc!et in the bearing may be chec!ed if
necessary they may be corrected at site as per the drawings.
&.'.&'. When ever %>P is not available use always thic! oil during rotation of
shaft over bearing.The type of oil may be used as servo cylinder &--- grade of
$>:.
&.'.&5. After installation of bearing in position the oil clearances may be
chec!ed after few rotation of the shaft. *ut the final oil clearances are to be
chec!ed after final coupling of the shaft. $n case of variation in side oil
clearances no cutting of babbitt metal is permitted at site. Any variation in
clearances may be counter chec!ed by measuring journal ( bearing bore dia.
*earing bore dia is to be measured by assembling and tightening of top ?
bottom halves of bearing.
&.'.&4. $n case of s!ew side oil clearances the investigation may be carried out
if necessary consult manufacturing unit.
&.'.&6. +nsure good contact between journal and babbitt metal of the bearing in
the center. Any minor high spot may be removed from the babbitt metal
while chec!ing with blue color. +nsure full contact of shaft over the jac!ing
oil poc!et also.
&.'.&8. Always cover rotor journal with the upper half bearing to avoid entry of
any sand particles etc. in the bearing . #uring pouring of oil the upper
bearing may be removed and replaced bac! after the pouring of oil.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
&.'.&.. After completing the reaming(honing and final tightening of coupling
bolts the wor! of bearing side pad yo!e !eys and oil guard fitting may be ta!en
up.
&.'.&1. *efore starting the side pad and top !eys ensure that the bearing is
perfectly level on parting plane. +nsure that the gap for the side pads are
parallel otherwise these are to be made by cutting(scrapping.
&.'.&0. After fitting of the bearing cap if the gap for the radial top !eys are in
taper a proper correction is to be made here. The bearing cap may also be
repositioned to achieve the parallelity of the !ey way. The cap may be re/
doweled after repositioning it but no taper are to be left on these area. $f
repositioning of cap is not helping then the cutting may be carried out in
bearing cap.
&.'.'-. The gap for the top pac!er of bearing may also be chec!ed. $n case of
any taper the same is to be corrected by cutting on bearing cap. ;ometime
the si=e of this pac!er comes to very low i.e. even below 6.-- mm. This may
be corrected by matching the cap and si=e for this pac!er may be !ept around
8.-- mm.
&.'.'&. >n all these bearing cap !ey a proper fitting and clearances are to be
maintained during assembly. These !ey of proper material are to be only used
and no welding deposits are permitted here. The new !ey may be made at site
by +3/'4 material if correct !ey are not available at site.
&.'.''. Use of local made shims in bearing may be avoided and shims supplied
from the wor!s with proper cutting of holes are to be used. +nsure drawing
re@uirement of ma"imum adjustment at site by A -.5mm in shim si=e from
manufactured condition.
&.'.'5. A proper care should be given during fitting of bearing oil guard ring
otherwise it causes the oil lea!age during operation of the machine through
pedestals. Parting plane joint of oil guard ring and duct should be feeler tight
and no elongation of holes on these area may be permitted.
&.'.'4. The bearing parting plane bolt are to be tightened to re@uired tor@ue only
no other method of tightening of these bolts may be used.
&.'.'6. Adjustment of shims between spherical(torus and bearing body is limited
to A-.5- mm in up and down and left right direction. this margin may be left
for emergency wor! during overhauling of the machine any adjustment during
erection and normal overhauling may be done by adjusting shims between
spherical(cylindrical seat and pedestal base only. Bor left and right adjustment
the complete pedestal of HP front and HP rear may be moved with the help of
their radial !eys.
The above discussed points were common for %ournal bearing
and combined thrust and journal bearing. 3ow some specific
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
points are detailed here for the assembly of combined Thrust
and %ournal bearing9
)emove all the thrust pads before placement of bearing in
position and store them in a proper place.
Pressure proper fitting of babbitt metal liner in the bearing body
including necessary pinch in the fitting of its liner.
#uring alignment of rotor along the bearing with respect to the
shaft by moving spherical seat of the bearing radially and
a"ially.
3o elongation of holes are to be carried out in spherical sat of
the bearing for the purpose of its alignment.
*efore deciding a"ial position of the bearing the a"ial position of the
rotor is to be determined. $f necessary the H.P. rear pedestal as a
whole may be shifted a"ially to ensure correct position of the
thrust bearing.
Align the thrust bearing in such a way that the thrust pad gap
achieved are prallel and no difference are noticed in front and
rear pad thic!nesses.
7ovement in the thrust pad should be ensured and a difference in
thic!ness of pac!ers including shims should be with in A -.&- mm
may be permitted on front and rear pad si=es in e"ceptional cases.
After ensuring the perfect alignment of the bearing the a"ial !eys
are fitted after assembly of upper half bearing. These a"ial !eys
are to be fitted in perfect parallel slots without any clearances.
The !eys are to be fitted in such a way that there is no movement
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
to the bearing during fitting of these a"ial !eys. 3ecessary dial
gauges are to be installed on bearing during fitting of these !eys.
After completion of a"ial !ey wor!s of the bearing the thrust pads
may be fitted in the bearing with a clearance of about -.&-(-.&6
mm.
*efore fitting of pads in the bearing ensure that there dimension
are made parallel to suit the front and rear slot si=e of the bearing
Csi=e between thrust collar and bearing bodyD.
Ater fitting of pads in the bearing ensure their free movement
over the bearing.
$nstall lower half bearing in position along with their pads and put
very small @uantity of oil on journal then rotate the rotor and put
blue color on the thrust collar of the rotor on both front and rear
side.
$nstall upper half bearing along with all pads and fi" their a"ial
!eys.
)otate the rotor and move A direction a"ially with the help of
wooden plan!s. )emove both halves of the bearing and see the
blue contact on thrust pads. $f necessary some cutting may be
carried out on the pads to achieve the color contact. This
e"ercise may be repeated few times to achieve the blue contact
+nsure a float of -.5- A -.&-mm during color matching of the
thrust pads. $f necessary the minor adjustment of shims may be
carried out in the bearing pads.
*efore installation of thrust bearing along with thrust pads in
position the both halves may be bolted out side and their pads
may be chec!ed for color contact over a surface plate also in
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
front and rear both sides. This will reduce the time cycle while
carrying out the color contact of the bearing with the rotor.
#uring overhauling of the unit the bearing contact are to be
rechec!ed and need correction. $n case of torus to cylindrical
type of bearing if the contact are not satisfactory then the
bearing and its seat may be remachined at wor!s. $n spherical
to spherical bearing the variation in contact if noticed can
be corrected by matching(lapping at site. ;ometimes the
heavy pitting mar!s are also noticed on same of the bearing
and these need correction by machining it.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
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STEAM TURBINE
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ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
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STEAM TURBINE
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ERECTION
CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(BUMP CHECK)
2. BUMP TEST
Th !"#!$ %$!&!'% %h%( #) *+&,#'* !-+& &!*#!$ %$!&!'%
,!).&,'+ h!) /' %0,1$+*.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ROLL CHECK)
;. ROLL CHECK
;.1. GENERAL DESCRIPTION
$n KWU machine the minimum radial clearances HP $P and ,P casing are
measured by actually by moving the casing radially at site while rotor is rotated
by hand. This is a very accurate and fast method of measuring the minimum
radial clearance of any of the casing.
The major variation in these reading may cause vibration in the machine
and obstruction in barring gear operation etc. ;uch facilities are not
available in many other designs of machine and causes longer duration in
erection and overhauling of the units.
After completing the alignment of rotors the casing alignments are carried out by
roll chec! method but e@ual importance should also be given to the centering of
HP and $P casing.
The centering of casing may not be fully sacrificed in comparison of rolling
test readings and a compromise between these two readings should be made.
The rolling test should be carried out in cold machine only.
;.2. PROCEDURE
ROLL CHECK OF HP AND IP CASING
5.'.&. Alignment and coupling of HP/$P and ,P rotors are to be completed before
starting the rolling test of the casing in normal case but this can be done
without coupling of ,P rotor also.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ROLL CHECK)
5.'.'. :entering of the casing on HP front HP rear $P front and $P rear spigot are also
to be completed before starting of the rolling test. These readings can be
compared as per the factory protocol also. Bi" temporary radial and a"ial
!eys of the casing before rolling test of casing. #uring dialing on spigot a
proper care should be ta!en that the dials are properly mounted over the
fi"ture and the fi"ture fabricated at site is strong enough to give the correct
readings. The point dial indicator may be used here for the better results of the
dial readings.
5.'.5. All the four jac!ing screw of HP and $P casing are to installed along with dial
gauges for monitoring of up and down and left and right movement of the
casing.
5.'.4. >ne number hydraulic jac! on each corner of the casing along with a spanner
on each corner for jac!ing screw are also to be made available.
5.'.6. #uring erection of machine the turbine rotor are generally rotated by hand with
the help of periphery holes on coupling. Two pipes of about &'6- mm long
along with a pin to suit the dia of periphery may be used for rotating the rotor
shaft. The initial jer! to the rotor is given by the help of crane and it is further
rotated by these pipes through periphery holes of the coupling. #uring
overhauling generally the jac!ing oil system is available and the rotation of
rotors are achieved with the hand barring of the machine.
5.'.8. *efore starting the rolling chec! it should be ensured that the rotor shaft is
absolutely free on manual rotation(hand barring as the case may be.
#uring manual rotation two persons are to be employed for this wor! and
during hand barring only one person is enough.
5.'... Always use thic! oil for rotation of rotor over bearing in absence of jac!ing oil
system. The type oil may be servo cylinder &--- grade C$>:D oil.
5.'.1. #uring the rolling test the temporary casing pac!ers are to be fitted with about
&.-- mm shims.
5.'.0. #uring the rolling test of any one of the casing the same is lifted first on all four
corners in a step of -.-6 mm with the help of hydraulic jac! and jac!ing
screw. The rotor is also rotated manually side by side with the lifting of casing.
The rotation of rotor and lifting of casing continued till it becomes little bit
tight on the seals of the casing
After this the casing is lowered by about -.-6mm and rotor is
rotated again if it is completely free. $n case the rotor is still tight
on its manual rotation the casing is further lowered by -.-6 mm
on all four corners. After ensuring the freeness of rotor it is again
rotated and casing is lifted simultaneously on front end till the
rotor rotation becomes tight on seals portion of the casing.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(ROLL CHECK)
As soon as the shaft becomes tight the lifting of casing and
rotation of shaft is stopped and dial readings on front end are
recorded. The average lift on front end of the casing is the bottom
clearance on front end of the casing.
After this the casing on front end is lowered by -.-6 mm and
freeness of rotor is ensured. $n case it is still tight the casing is
further lowered by -.-6 mm. >n front end and the freeness of
rotor is achieved. 3ow the rear end of the casing are lifted similar
to front end and bottom clearance of rear end are recorded . After
recording the bottom clearance of front and rear end of
individual casing the casing is lowered with the help of hydraulic
jac!s and jac!ing screws to its original =ero/=ero position.
)epeat similar operation of rotating the rotor and lowering the
casing on front and rear end for deciding the top clearance in
front and rear end of the casing. *efore starting the rolling test in
downward direction of the casing remove about &.-- mm shims
from each pac!er of the casing but !ept the casing on
hydraulic jac!s and jac!ing screws on its original position. The
casing is again brought bac! to its original position by
installation of the shims bac! to the pac!ers of the casing after
recording the top clearances of the casing.
After recording the up and down rolling test values the radial
!eys of the casing are removed and again rolling test for left
and right direction are done similar to up and down. #uring this
process the radial dial on the casing are also installed. After
this chec! the casing is brought bac! to its =ero position in radial
direction also.
After completing the rolling test readings of one of the HP($P
casing in up(downand left(right direction the clearances are
readjusted as re@uired at site in radial direction by moving the
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CRITICAL ACTIVITIES
(ROLL CHECK)
casing with the help of temporary radial !ey or shims on the casing
pac!ers. The casing is then loc!ed on four corners and final
dial readings of spigot are recorded on front and rear end.
$mmediately after this the final radial !ey of the casing are fi"ed
and the loc!ed of the casing are released for fitting of the final
casing pac!ers. The final spigot dial reading are repeated and
confirmed with the earlier readings.
5.'.&-. After doing the full rolling test and fi"ing of a final radial !eys and
pac!ers of one of the casing the rolling test of another casing is done including
the fitting of final !eys and pac!ers.
5.'.&&. 3ecessary offset in the radial clear/ance is also !ept before fitting of
final pac!ers of the casing toward the lift of the shaft during operation of the
unit.
5.'.&'. 3o inlet and outlet pipes are to be welded with the casing till completion
of rolling test and installation of final !eys and pac!er of the casing.
5.'.&5. )adial clearance of the casing are to be ensured with reference to the
factory supplied protocol also.
5.'.&4. After fitting of final !eys and pac!ers of the casing the final spigot dial
values of HP front HP rear $P front and $P rear casing are to be recorded
for future reference in the protocol.
5.'.&6. The horn drop readings are also to be chec!ed after the fitting of final
pac!er of the casing.
5.'.&8. $n case of $P casing the roll test readings are to be ta!en with the $P
front end rear shaft scales. The spigot dial readings are also to be ta!en over
the spigot of shaft seales.
5.'.&.. #uring rolling test of the HP and $P casing if the rotor is rotated over the
jac!ing oil then the adjustment of readings are to adjusted for the lift of the
rotor also.
5.'.&1. Bour numbers &.-- mm undersi=e pac!ers for HP ? $P casing may be
made during erection and supplied to customers as T?P items for further roll
test during overhauling of the unit. $f any taper is left on final pac!ers of the
casing then these four pac!ers may be made to similar taper also.
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CRITICAL ACTIVITIES
(ROLL CHECK)
;.;. ROLLING TEST OF L.P. INNER CASING
5.5.&. The rolling test of ,.P. inner casing is done similar to the HP or $P casing but
both side joints of ,.P. inlet bellows are !ept free or bellow itself are not
positioned at all till completion of rolling test. *ut during overhauling the
rolling test is done with already welded bellows.
5.5.'. )olling test of ,.P. inner casing is done after the nec! welding of condenser
andstiffener pipes inside the condenser. This include the welding of stiffener
pipes of ,.P. casing and gusset plates also.
5.5.5. After rolling test of the casing the final radial !eys of the 2usset bloc! and
casing pac!ers on all four corners are installed.
5.5.4. 3ecessary offset in the radial clearances of the casing is also !ept before
fitting of final ,.P. inner casing pac!ers.
5.5.6. )adial clearances of the casing are to be ensured to the design values. $n case
of any variation the matter may be referred to the designers.
5.5.8. $f the rotor is rotated on jac!ing oil then the rolling test readings are to be
adjuted for the lift of the rotor also.
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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)
<. CATENARY AND ALIGNMENTS
<.1. G'&!$ D)%&#1+#0'
The catenary of the machine is very important for a turbine and 2enerator
assembly to achieve proper alignment of various rotors and loading on their
bearing. Any deviation may lead to various operational problem in the
machine li!e high shaft vibration high bearing vibration high babbitt metal
temperature of the bearing etc. To avoid these problems it is necessary to
maintain the catenary of the machine during erection and subse@uent
realignment(overhaul of the unit. 7any times it is observed that though the
alignment of rotors are within limit but the catenary as a whole get deviated
from the prescribed design value of the machine. $n order to avoid such
derivation a need is felt to devise a procedure which shall ensure rotors
alignment alongwith proper catenary of the machine.

#uring first few years of the operation of the unit the possibility to the
disturbance of the catenary are much more due to settlement of the foundation
frame.
$n each overhaul of the unit the catenary of the machine is to be corrected.
The ,.P. front and ,.P. rear pedestal are directly grouted here without any
separate base plate. As such any correction on lifting or lowering. These
pedestals are not very convenient so if necessary the rotor may be lifted or
lowered with respect to pedestal seal bore and re@uired catenary may be
achieved. $n e"treme cases these pedestals may be even regrouted during
major overhauls of the unit to correct the catenary of the machine.
<.2. P&0%*.&

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STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)
4.'.&. $nstall a bench mar! plate near ,.P. rear pedestal as height of the machine
center line with the consultation of civil +ngrs at site. A plate of '-- m.m "
5-- m.m si=e with '- m.m thic!ness machined(ground on top side may be
welded over a $ *eam or a channel in level condition. This plate is to be
installed very carefully as this will be a future reference for setting up the all
elevation of the machine.
4.'.'. )ecord half bore error of all the four pedestals and confirm the readings with
the factory records also. The half bore error may be chec!ed in both upper half
and lower half of the pedestal and same may be punched on both halves in
left and right side for all future references of the machine.
4.'.5. #uring alignment of pedestal at the time of grouting with conbe"tra cement
set the height of the pedestals as per re@uired catenary of the machine
considering Avalue for the half bore error of the pedestals. While setting the
height of the pedestals it should be !ept in mind that the height for the center
of the pedestal bore are to be !ept as per the catenary of the machine not
the parting plane of the pedestal.
4.'.4. Bor better results four water level jar connected to each other with a
polythene pipe may be installed on each pedestal. The #.7. water may be
used here and lea!age through polythene tubes should be avoided fully while
ma!ing the connections. These jars may be fabricated at site by about &'6 mm.
dia pipe with a plate welded in bottom and then machined for better seating on
pedestal base. The height of the jar may be !ept as about &.6 mm. A depth
micrometer installed and clamped over a magnetic base is also re@uired for
measurement of the water level in the jar. The micrometer point is to be made
very sharp by grinding it. Here the magnetic base of the -/&-mm dial gauge
may be used.
4.'.6. .#uring measurement of water level in the jar the micrometer is to be !ept
appro"imately in center of the jar. The micrometer along with the magnetic
base to be transferred from one pedestal to another pedestal very carefully
so there is no disturbance to the height of the micrometer. All the necessary
care are to be ta!en during this measurement i.e. there should not be any air
bubble in the polythene pipe and the polythene pipe should be !ept as
stationary.
4.'.8. While finali=ing the catenary of the machine these measurements are to be
repeated 5/4 times in a day at different intervals to avoid any possibility of the
error.
4.'... The height of the ,.P. rear pedestal is the reference point for setting the
height of all other pedestal and ,.P. base plates. The ,.P. rear pedestal height
is to be first made with the benchmar! plate as per the center line of the
machine with the help of water level jar.
4.'.1. The benchmar! plate is to be preserved for all future references.
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ERECTION
CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)
4.'.0. The catenary is to be counter chec!ed after grouting all the pedestals as well
as after final alignment of the rotors. The final value of the catenary may be
wor!ed out as center of the shaft on each pedestal bore after ta!ing the final
seal bore readings. The final catenary should match with the design value of
the catenary otherwise a necessary correction may be carried out.
4.'.&-. After ensuring the re@uired catenary of the machine the coupling
alignments are to be made as parallel coupling.
4.'.&&. The value of the catenary given over the drawing are theoretical value
calculated by the designers but due to the human error in site measurements
some time the correct coupling alignment are not achieved then an alternate
method for chec!ing of catenary may also be used i.e. optical measurement
method or a method by which direct journal heights are ta!en on each bearing
in place of pedestal height.
4.'.&'. Bor measurements of direct journal height a special fi"ture is to be
fabricated and necessary information about it can be separately given by P;/T;
if such necessity arises.

5. HORN DROP TEST
5.1. G'&!$ *)%&#1+#0'
*y horn drop test the loading of the casing on each corner is determined. The
horn drop test is repeated at various stages in individual casing i.e. first
without connection of any pipe lines the horn drop readings are recorded then it
is compared after welding of inlet outlet and e"traction pipe lines etc. The horn
drop readings are very important in HP ? $P casing. Birst the proper horn drop
readings are made without connection of any pipe lines and then the reading
are ta!en after welding of all pipe lines on HP ? $P casing. As such the
influence of these major pipe lines are notices on each corner of HP($P
casing by comparing the horn drop test readings. The horn drop test will
indicate the @uality of wor! during assembly(welding of pipe lines with the HP ?
$P casing.

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ERECTION
CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)
This is a very important chec! and may cause serious problem in operation of
the machine li!e high vibration in the machine failure of barring gear in hot(cold
machine obstruction during e"pansion of machine etc. $n horn drop test a drop
is measured on an individual corner of the casing with the help of a dial
indicator by removing the support of individual corner and then it is compared
with the opposite corner. As such this gives an indication of indifferent loading
of the casing. $n )ussian design machine the value of direct dyno"metre
loadings are recorded in place of this horn drop test.
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ERECTION
CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)
5.1.1. P&0%*.&
6.&.'. After placement of HP and $P casing on four temporary pac!ers ensure that the
each corner of the casing is loaded on temporary pac!er and if necessary the
shims may be given on pac!er for loading of the casing. The load of shaft is also
ta!en on transport device during this stage.
6.&.5. After transferring the load of the rotor on bearing and ensuring the casing
centering with respect to shaft the horn drop chec! may be carried out.
6.&.4. *efore ta!ing the horn drop reading ensure that the enough clearance is
available on front ? rear portion of the shaft with their seals in the casing
inside. After completing the centering of the casing the some may be lifted by
-. '- mm on all four corners by providing shims. This will help in avoiding the
touching of seals with the rotor during the horn drop test readings.
6.&.6. 3o adjustment on pac!er of the HP front and HP rear pedestals are to be
carried out after ta!ing the horn drop test of the casing $n case if any
adjustment is carried out on these pedestal pac!ers then horn drop test are to
be repeated again.
6.&.8. 3o piping may be connected to HP ? $P casing till initial horn drop readings
are over. The piping wor! should not be postponed for want of horn drop the
only thing the last joint with HP($P casing may be left free till completion of horn
drop chec!.
6.&... While recording the horn drop readings the casing must be absolutely free and
even the radial and a"ial !ey of front and rear portion of the casing are either
to be removed fully or these are to be made completely free by removing their
shims etc. Actually during this stage of erection only temporary a"ial and
radial !eys are fitted in the casing and even they carry some shims also.
*efore ma!ing the casings free on a"ial and radial !ey portion the dial
gauges are to be installed to monitor the movement of the casing on radial
and a"ial direction. $mmediately after the completion of the horn drop test
these !eys(shims may be installed bac! and centering of casing may be
rechec!ed before further wor!s.
6.&.1. $n HP casing the initial horn drop test may be done even after fitting of breach
nut assembly and HP e"haust elbow of both sides.
6.&.0. $n $P casing the initial horn drop test may also be done after fitting of $P inlet
pipe lower half assembly but this pipe of upper half casing should not be
fitted till completion of the horn drop test.
6.&.&-. All the four %ac!ing screw and hydraulic jac! on each corner of the
casing are to be installed for the horn drop test readings. A dial indicator is also
to be installed on each corner of the casing for measuring the drop of the
casing.
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(CATENARY AND ALIGNMENTS)
6.&.&&. After initial centering of the casing the each corner pac!er may be
fitted with a shim of about & mm. for further adjustment during the horn drop
test.
6.&.&'. #uring the horn drop test the individual pac!er of the casing is
removed and the load of that corner is supported over the jac!ing screw of the
casing. 3ow gradually the jac!ing screw is also relieved with the help of
hydraulic jac! on that corner and drop reading is recorded. This is repeated
for each corner of the casing. $n case of variation in left and right side
reading the drop is adjusted by A adjustment of shims from left to right side
or vise/versa. 3o subtraction ( addition in shim si=es from outside is done
here and only the shims are adjusted from left to right or vise versa till e@ual
loading are achieved in left(right side of individual casing. The si=es of these
casing pac!ers are recorded after completion of horn drop to avoid any
confusion at a later date while fitting the final pac!ers.
6.&.&5. While recording the horn drop readings the drop on each individual
corner may be controlled with the help of %ac!ing screw so that during this
test the casing is not touching with the shaft in gland portion of the seals at all
and enough clearance is left there to avoid damage to the seals inside the
casing.
6.&.&4. #uring the initial horn drop the best reading within -.-6(-.-8 may be
achieved by fine adjustment of the pac!er shims. The comparison in horn
drop value should always be made in left and right side only of an individual
casing.
6.&.&6. $n case of HP casing the drop on rear end is so high that unless the
casing is loc!ed on diagonally opposite end the horn drop chec! is not possible.
Therefore while recording drop on HP rear end the front end of the casing
diagonally opposite to it should be loc!ed with casing clamp. The pedestal
is also re@uired to be loc!ed on all four side with its sole plate with the help
of the clamps. $n case of $P casing no loc!ing of any corner of the casing is
necessary during the horn drop test.
6.&.&8. The final pac!ers on HP ? $p casing are installed only after completing
the rolling test of these casing. The horn drop reading for an individual casing
may be recorded after the fi"ing of final pac!ers also. $f necessary a fine
adjustment may be carried out at this stage to achieve correct value of the
horn drop reading.
6.&.&.. After completing the welding of all pipe lines with the casing the horn
drop readings are repeated again for comparison with the earlier readings.
These readings are ta!en along with its radial and a"ial !eys of the casing.
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6.&.&1. #uring this stage e"actly this can not be defined that how much
variation is permitted on these values of horn drop readings. *ut this
variation will indicate the influence of the piping load on the HP($P casing
caused due to welding(connection of various pipe lines with the casing. The
variation in horn drop readings are permitted as long as sufficient positive
loading is there on each corner of the casing. *ut if any corner of the
casing is fully unloaded(heavily loaded then there is no choice left and pipe
lines are to be corrected by dismantling it and ma!ing again a free joint with
the casing.
6.&.&0. #uring variation of horn drop reading no correction is to be made on
casing pac!ers by adjustment of shims etc. The variation at this stage is
caused due to the piping pull(push only so if any correction is re@uired then
the same may be carried out in piping joints and support etc. And any
adjustment in piping supports can be carried out only after disconnecting the
pipe line with the casing. +ven some time it is necessary to cut the individual
or more piping joint for correction of horn drop readings.
6.&.'-. The variation in horn drop reading of left and right side of a casing may
be permitted upto a difference of 6-E.
6.&.'&. The horn drop readings are not ta!en for ,.P. inner outer casing due to
its fabricated structure and the parting plane of the casing are leveled on
four corner with the help of water level jar arrangements.
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ERECTION
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(SWING CHECK)
=. SWING CHECK
=.1. GENERAL DESCRIPTION
The swing chec! is the measurement of radial throw caused due to
coupling face geometric form of the two rotor coupled together. This is
measured on opposite end of the coupling and at the free end of the rotor. The
higher swing chec! value may cause higher shaft vibration higher bearing
shell temperature etc. The value of swing chec! depends on a"ial runout of
coupling faces the diameter of the coupling and the length of the rotor. #uring
the machining of rotors in the wor!s some tolerances are permitted by
#esignerFs on the coupling faces of the rotor resulting to some swing chec!
values. The ma"imum swing chec! values permitted caused due to the
above tolerance for different diameter and length of the rotor can be
wor!ed out from the enclosed graph. However it is recommended to !eep the
minimum swing chec! values for better results during operation of the machine.
$n a multi rotor Turbine/2enerator system it is essential to measure the swing
chec! value in both e"treme end and where the weight of the rotors are light.
Bor e"ample '--('&- 7.W. KWU machine with )ussian 2enerator and
static e"citation system the swing chec! values are measured on HP rotor front
end only. $n 6-- 7.W. machine the swing chec! values are measured in H.P.
front end and on e"citer rear end. After having general e"perience of number of
'-- 7W ? 6-- 7W units a necessity is felt to measure swing chec! value on
$P rotor front end also for better results during operation of the units. This can
be done initially during erection with temporary coupling bolts on ,P/$P
coupling before reaming(honing of coupling. Any variation in swing chec!
values may be corrected without any hesitation during erection of machine.
Any compromise at erection stage may cause serious problem during
operation of the unit and any correction becomes much more tedious a later
STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(SWING CHECK)
stage. The correction may be carried out either by interchanging the
coupling position or by correcting the coupling faces by
scrapping(cutting in consultation of #esigners.
=.2. PROCEDURE
8.'.&. *efore placement of 7odule()otor in position the coupling faces of all the
rotors are to be measured for concavity(conve"ity of their coupling faces. This
can be chec!ed with the help of a thin rectangular light weight straight edge.
3o conve"ity is permitted on these coupling faces however a concavity of about
-.-5(-.-4 mm is permitted. $n case of any variation the matter may be
referred to manufacturing units.
8.'.'. After placement of individual 7odule()otor the coupling faces are to be
measured for a"ial runout before ta!ing up alignment of various rotors. The
HP rotor rear coupling face can be measured after placing it on both of its
bearing. The $P rotor faces are to be measured after placing $P rear end on
bearing and front end on lifting tac!le. ;imilarly ,.P. rotor may be placed on
bearing on its rear end and front end supported on lifting tac!le. Any variation
on a"ial runout on coupling faces for more then the -.-' mm. may be referred
to #esignerFs before ta!ing up further wor!s.
8.'.5. After completing final alignment of various rotor they are to be coupled
with temporary bolts considering their a"ial runout(geometric form of the
coupling faces.
STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(SWING CHECK)
8.'.4. #uring coupling with temporary bolts the higher plane of one of the rotor
face is to be coupled with lower plane of another coupling face of the rotor.
8.'.6. #uring coupling on temporary bolts the uniform tightening on all the four
temporary bolts are to be ensured otherwise it will disturb the swing chec!
value of the rotor.
8.'.8. Birst $P/,P coupling is to be made with temporary bolts and swing chec! on $P
rotor front end is recorded. After this only HP/$P rotor is to be coupled with
temporary bolts and the swing chec! value on HP front rotor is recorded.
8.'... #uring swing chec! of $P rotor its front end is to be supported on lifting
tac!le without ma!ing any connection between HP/$P rotor.
8.'.1. While recording swing chec! of HP rotor the front end of the rotor is to be
supported on lifting tac!le.
8.'.0. #uring swing chec! the lifting tac!le are to be fitted properly. The tie rod of
lifting tac!le should be ensured for correct fitting of its spherical bearing and
7oly!ote should be applied on these spherical bearing for their free
movement. These spherical bearing should not obstruct the movement of
shaft radially during chec!ing of its swing chec! value.
8.'.&-. After ta!ing the load of the rotor on lifting tac!le ensure that the rotor is
not disturb radially due to fitting of lifting tac!le.
8.'.&&. #uring chec!ing of swing chec! measure radial movement of rotor on
parting plane and rotate the rotor either on jac!ing oil with hand barring or with
the help of +.>.T crane with thic! oil on bearings. Avoid jer! during rotation of
rotor while recording the swing chec! values.
8.'.&'. After ensuring the swing chec! values as per the graph with on
temporary coupling bolts the HP/$P and ,P/$P coupling may be cleared for
reaming ( honing of the coupling holes. Any variation need correction of the
coupling before reaming(honing of the holes.
8.'.&5. The final swing chec! value of HP front rotor is to be recorded after
fitting( elongation of all the coupling bolts of HP/$P ? ,P/$P rotors. Any variation
in readings may be referred to the #esignerFs. Bor improvement of the swing
chec! values the indifferent tightening and non/se@uential
8.'.&4. #uring chec!ing of swing chec! readings the initial few rotations are to
be given to the rotor to avoid initial sag and then only the readings are to be
recorded.
8.'.&6. ;imilar method is to be adopted while chec!ing the swing chec! value
of the e"citer e"cept the rotor is hanged on the suitable si=e of sling in place of
the lifting tac!le.
8.'.&8. While recording the swing chec! initially with temporary bolts for HP
? $P rotor the fitting of eight number temporary bolts are preferred in place of
four bolts on the coupling.
STEAM TURBINE
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ERECTION
CRITICAL ACTIVITIES
(SWING CHECK)
STEAM TURBINE
500 MW
ERECTION
CRITICAL ACTIVITIES
(COUPLINGS > ALIGNMENTS
OF ROTORS)
?. COUPLINGS > ALIGNMENTS OF ROTORS
?.1. GENERAL DESCRIPTION

The coupling on turbine shaft are generally rigid coupling but in case of
,.P. rotor sometime the coupling head are shrun! fit and remachined. The
basic function of any coupling is to connect two or more shaft together to form
a shaft assembly. The number of shaft mainly depend upon the rating of the
machine.
A very high accuracy is re@uired during manufacturing of these rotor shaft
at wor!s. The a"ial runout on the coupling face may not e"ceed -.-' mm.
and an additional chec! is also made at wor!s(site to ensure that the geometry
of the entire coupling surface does not deviate by more then the -.-' mm.
e"cept the concavity on the coupling face which is permitted upto -.-5(-.-4
mm.
The radial and a"ial alignment of the various shafts are to be completed
before their coupling and alignments are to be done in such a way that the
entire shaft assembly follow the continuous deflection curve given over the
drgs. for a particular machine. The coupling chec!s determines both the radial
and a"ial position of the two adjacent coupling flanges relative to one another.
The radial measurement are performed on the circumference of the
couplings and the a"ial measurement are performed on outer most diameter
of the coupling. #uring coupling of the two shafts it should be ensured that the
no stresses are e"erted as a results of the coupling each other shaft.
After completion of the alignment and coupling of the shaft the casings are
aligned radially and a"ially. Here e@ual importance is given to the radial ?
a"ial alignment of stationary parts to avoid any rubbing during operation of the
machine due to e"pansion of stationary and rotary parts.
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#uring the alignment of two coupling both are to be turned in same direction
and by the same amount when the measurement are ta!en to avoid the
influence of the a"ial ? radial runout present in the shaft caused due to the
machining.
?.2. PROCEDURE
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OF ROTORS)
..'.&. *efore placement of module(rotor in position chec! and record the coupling
hole and journal dia of the shaft.
..'.'. :hec! coupling faces for the concavity(conve"ity with the help of a
thin rectangular straight edge before placement of module(rotor in position.
..'.5. :hec! spigot and recess of the coupling and ensure their fitting before
placement in position.
..'.4. Place the module(rotor in position and chec! the radial runout of journal and
a"ial runout of the coupling faces independently of each shaft. #uring
chec!ing of radial and a"ial runout of the shaft place H.P. rotor on both of its
bearing and $P(,P rotor one end on its bearing and another end on the lifting
tac!le. The radial and a"ial face runout on the shaft should be within -.-' mm
accuracy. Any variation may not be permitted here and matter may be referred
to the designerFs.
..'.6. The HP$P ? ,P rotor are aligned together and then their couplings are made.
After fully completion of HP($P ? $P(,P coupling with tightening of their final
bolts the complete shaft is cleared for 2enerator rotor alignment.
..'.8. #uring initial alignment of HP($P ? $P(,P rotor the radial chec!s are generally
done with the help of depth micrometer and a"ial gap are measured with
the slip gauges. After completion of the radial alignment the rotor are inserted
in their spigot even with some minor variation in their a"ial gap values.
..'... #uring final alignment only the a"ial gap values are chec!ed at 0-o on four
places by rotating both the rotor together and average of these four reading
are ta!en. The radial alignment reading along with a"ial gaps are necessary
wherever the effective spigot are not e"isting in two couplings i.e. in case of ,P
/ 2en coupling the radial dial reading are also ta!en.
..'.1. Avoid rotation of two shaft in their spigot. $f necessary these may be rotated
after ta!ing out from their spigot.
..'.0. #uring alignment of shafts the adjustment of shims in bearing torus may be
fully avoided. The margin of A -.5- mm. in height ? left(right direction may be
!ept for emergency wor!s only. Any adjustment during erection and normal
overhauling may be done by adjusting shims between spherical(cylindrical
seat and pedestal base only. Bor left and right adjustment the complete H.P.
front and HP rear pedestal may be moved with the help of their radial !eys.
..'.&-. The final pac!ers of the pedestal and base plates are fitted before the
grouting of the pedestal itself and here no adjustment is necessary during
erection of the machine. *ut during overhauling of the machine the adjustment
may be carried out in these pac!ers for correction of catenary of the machine.
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(COUPLINGS > ALIGNMENTS
OF ROTORS)
..'.&&. #uring alignment of rotor ma!e HP($P and $P(,P coupling gap parallel.
After completion of final alignment no adjustment of pac!ers and !eys etc are
permitted on pedestals and bearing the final alignment of HP($P ? $P(,P rotors
should be chec!ed after fitting of all the final !eys and pac!ers of the pedestals.
..'.&'. After alignment couple the HP/$P ? $P/,P rotors on temporary bolts.
)ecord coupled runout of the rotor and ensure that the coupled runout is
not more then -.-5 mm. in any where in the journal as well as in coupling
area. *efore coupling of rotor on temporary bolts record their spigot
clearances by actually moving the rotor radially.
..'.&5. #uring erection $P/,P swing chec! on $P front and HP/$P swing chec!
on HP front are to be recorded on temporary bolts. These reading are to be
ensured within the design limit.
..'.&4. *efore alignment(coupling position the two shaft adjustment to each other
depending upon the higher and lower point of the shaft with respect to their
a"ial face measurement values.
..'.&6. The HP/$P ? $P/$P coupling may be cleared for reaming(honing after
ensuring the runout and swing chec! values of the rotors. $n case of variation
the cause of the error may be identified and corrected before further wor! of
reaming and honing of the coupling.
..'.&8. #uring coupling of rotors two taper pins may be used for proper
alignment of coupling holes so that there is minimum enlargement of holes
are done at site during reaming(honing. Unnecessary enlargement of holes
may be fully avoided during reaming(honing at site as this may cause
serious problem at a later date during overhauling of the unit.
..'.&.. As for as possible ream(hone all the coupling bolts holes to
same si=e. $n e"ceptional cases only the variation in hole si=es are
permitted. +ach hole during honing should be chec!ed for bananas shape with
the help of a parallel ground straight pin of -.-'(-.-5 undersi=e. 3o banana
shape is permitted in any of the hole. The hole should be made to -.--6 mm
accuracy.
..'.&1. All the coupling bolts are to be machined and ground by -.-'(-.-5 mm
undersi=e then the hole dia. These bolts are to be fitted with thumb pressure
only and no additional force is recommended while fitting these bolts.
..'.&0. A very thin layer of moly!ote may be applied on all the coupling
bolts during their fitting. The moly!ote should not be applied on seating
face of the coupling bolts. This may cause in brea!ing of their loc!ing pin
during elongation of coupling bolts.
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CRITICAL ACTIVITIES
(COUPLINGS > ALIGNMENTS
OF ROTORS)
..'.'-. All the coupling bolts are to be balanced before finally fitting(tightening
in position. These are to be balanced within an accuracy of 6 gms each along
with their nuts. $n case all these bolts are of e@ual si=e then their weight must
be e@ual. $n e"ceptional cases the &1-o opposite bolts may be made of e@ual
weight.
..'.'&. #uring tightening of coupling at any stage first tighten four bolts on 0-o
location. Always tighten bolts in proper se@uence with &1-o opposite
bolts. These bolts are to be elongated to the value given over drgs.
..'.''. #uring tightening of coupling the radial runout on journal and
coupling may be chec!ed at various stages during tightening of bolts. The
final coupled runout should not be more then -.-5 mm. on coupling and journal
of the shaft.
..'.'5. After final tightening of ,P/$P and HP/$P coupling the swing chec!
value on HP front rotor is to be rechec!ed. $n case of variation in value a
proper correction is to be made with consultation of designerFs. The
indifferent or unse@uential tightening for achieving the swing chec! value or
coupled runout value may be fully avoided. this may cause unnecessary
stresses on the coupling.
..'.'4. After completing the coupling wor! the casing radial and a"ial
alignment may be done.
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ERECTION
CRITICAL ACTIVITIES
(W$*#'6 0- )+!, #'$+ !'* "h!.)+
1#1 $#') 7#+h HP !'* IP %!)#'6)
W$*#'6 0- )+!, #'$+ !'* "h!.)+ 1#1 $#') 7#+h HP
!'* IP %!)#'6
$n '&- 7W machine the HP Turbine is supplied with two inlet and two e"haust
flanges for connection of the pipe line.but in case of 6--('6- 7W HP Turbine
the casing is supplied with four inlet flanges also. As such in '-- 7W machines
only two +;G control valves are used in the system. Whereas in 6--('6- 7W
machines $t may be either two +;G oontrol valves or four +;G control valves to
cope with the design of the casing.
;imilarly in '&- 7W machines the $.P. casing is supplied with two inlet flanges
and eight number e"haust branches or either two e"haust branches only along
with two inlet flanges. These eight number e"haust branches are distributed
four on each side of the casing and each four branches are joined together with
one common pipe while connected to ,.P. casing. The 6-- 7W $.P. casing is
similar to the '&- 7W $.P. casing but some time these are supplied with four
numbers of $.G. control valves also. The inlet lines from each two control valves
are joined together and ma!e one connection with the $.P. casing in bottom. As
such in '&- 7W machines only two $.G. control valves are used but in case of
6-- 7W machines there can be either two $.G. control valves or four $.G. control
valves.
After completion of the rolling test the installation of final !eys and pac!ers of the
H.P. and $.P. casing the same can be cleared for welding of inlet and outlet
pipelines. The main steam inlet line from main steam strainer to the control
valves and then from control valves to the H.P. casing need much more care
during erection ( welding of the pipelines. ;imilarly the Hot )eheat lines
between two Hot )eheat strainer to the control valves and from control valves to
the $.P. casing also need e@ual care during erection ( welding of these pipelines.
These pipelines are directly affecting the performance of the turbine during
operation of the machine and a necessity is felt to fully involve the turbine
+rection +ngineer in erection ( welding of the pipelines at site along with the
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STEAM TURBINE
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ERECTION
CRITICAL ACTIVITIES
(W$*#'6 0- )+!, #'$+ !'* "h!.)+
1#1 $#') 7#+h HP !'* IP %!)#'6)
Piping +ngineers. The piping connection between $.P. casing to ,.P. casing i.e.
cross around piping also need proper care but due to its construction with
number of bellows in the system. Present method of erection ( welding much of
the problems are not faced during operation of the machine. However if proper
care is not ta!en here then that may cause the unnecessary loading on the
various bellows of the piping and reduction in their life. $n case if proper care is
not ta!en during erection ( welding of 7; inlet :)H ? H)H connections with HP
? $P casing a load will be transfer from the pipe line to the casing. Which may
cause vibration in the machine obstruction in e"pansion of the machine
obstruction of barring gaer operation in hot ( cold machine higher babbit metal
temperature and failure of brg. babbit etc. during operation of the machine.
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STEAM TURBINE
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ERECTION
CRITICAL ACTIVITIES
(W$*#'6 0- )+!, #'$+ !'* "h!.)+
1#1 $#') 7#+h HP !'* IP %!)#'6)
@. PROCEDURE
1.&. The following points are to be ta!en care while welding 7; :)H H)H
pipelines with HP ? $P casing and control valves ( strainers.
1.&.&. The HP ? $P casings are to be cleared in all respects after fitting of final pac!ers
and a"ial ( radial !eys of the casing.
1.&.'. The +;G ? $G valves are to be cleared after fitting of their servomotors and then
levelling including the correct elevation etc.
1.&.5. The e@uivalent insulation weight is to be given on each control valve befor
connection of any pipeline with the valve. The change in hanger value of the
control valve is to be adjusted bac! by lifting the valve with the help of hangers.
The control valve hanger reading should remain same as before and after
installation of e@uivalent insulation weight on the valve. After this all the three
hangers of each valve are to be loc!ed to avoid any movement of the valve in
upward direction in case the e@uivalent insulation weight is removed or any of
the servomotor is removed. *efore starting of any welding with the control valve
the valves are to be loc!ed for their movement.
1.&.4. +rection and welding of 7; line upto 7; strainer and H)H strainer are to be
completed first including either their insulation or e@uivalent weight is to be
given for their insulation weight in the lines. These lines should be in perfect
floating condition on their hangers before ta!ing up the further wor! of 7; ?
H)H lines upto the +;G ? $G control valves.
1.&.6. $nstall 7; ? H)H lines between strainer and control valves and weld all the
inbetween joins of the pipelines e"cept the end joints with the valves and
strainers. These lines are to be erected in such a way that both the end joints
remain free and parallel with the strainer and control valve after ta!ing their load
on hangers. The freeness of joints are to be ensured after giving the e@uivalent
insulation weight of the lines.
1.&.8. Weld 7; ? H)H lines with the strainers and again ensure the freeness (
paralalllity of 7; ? H)H lines with the +;G and $G control valves. Any minor
variation may be readjusted on hangers to obtain the freeness of the joints with
the control valve.
1.&... $nstall the 7; and H)H lines between control valves and HP ($P casing . 3ow all
the in between joints may be !eeping the end joints free with the valve and the
casing. The erection of these lines are to be done in such a way that freeness
and parallelity of end joints are achieved after fully floating the pipe lines on their
hangers. The e@uivalent insulation weights are also to be added during erection
of these pipe lines before welding the end joints.
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ERECTION
CRITICAL ACTIVITIES
(W$*#'6 0- )+!, #'$+ !'* "h!.)+
1#1 $#') 7#+h HP !'* IP %!)#'6)
1.&.1. After ensuring the freeness and parallelity of the end joints between +;G control
valve and HP casing the same may be welded together. *ut the stress
relieving of all the in /between joints of the lines are to be completed before
ta!ing up wor! of the above last two end joints . ;imilar proceedure may be
followed for the lines between $ G valves and $P casing also.
1.&.0. Weld left and right 7; and H)H joints togethers with the HP and $P casing to
avoid any left and right loading on the casing . during welding the left and right
movements of casing may be monitored by installing the radial dial gauge on the
casing.
1.&.&-. The :)H lines are to be erected on their permanent hangers and the
joint with the HP casing are to be made free (parallel after floating the pipe lines.
The left and right side casing joints are to be welded together similar to 7;
lines but before weling of these line the in/ between joints are to be completed
first . The e@uvalent insulation weight is also to be given on these line while
chec!ing the freeness of end joints with the HP casing.
1.&.&&. The horn drop readings are to be recorded for both HP and $P casing
after copletion of the job including insulation of pipe lines and control valve etc.
@.2. SPECIAL CARE
1.'.&. $f possible !eep the insulation weight and servomotors on +;G and $ G control
valves during erection (welding of these 7; ? H)H lines from strainers to the
valve and casing . $f the above condition are fulfilled then there no need of any
loc!ing of the valves during the welding of any pipe lines.
1.'.'. The control valves hanger readings are to be measured with the inside
micrometer in various stages and changes are to be monitored properly . The
readings are to be measured in the following stages 9/
After complete leveling of +;G and $G control valves with their
servomotors
After putting the e@uivalent insulation weight on the control
valves.
After readjustements of control valve height e@uivalent to
insulation weight.
After connection of 7; ?H)H lines with the strainers .
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250 MW
ERECTION
CRITICAL ACTIVITIES
(W$*#'6 0- )+!, #'$+ !'* "h!.)+
1#1 $#') 7#+h HP !'* IP %!)#'6)
After connection of 7; ? H)H lines with the HP ? $P casing .
After complete insulation of control valve and pipings.
1.'.5. +nsure proper clraning of 7; and H)H lines between controls valve and casing
as these lines are not covered in steam blowing operation . Proper care is to be
ta!en during erection of these lines to avoid entry of foreign material.
1.'.4. The steam blowing of the 7; and H)H pipe line are to be carried out after fully
completing the erection (welding of lines from control valve to the HP and $P
casing .
1.'.6. All the four corners of the casing may be loc!ed with the casing clamp during
welding of piping joints to avoid movement of casing radially.
1.'.8. The load of the upper half H)H pipe upto the flange supplied by turbine supplier
is ta!en by the $P casing and by the piping hangers. This may be ta!en care
while erecting the H)H lines.
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