LARSEN & TOUBRO LARSEN & TOUBRO

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 STEP-7
STEP-7 STEP-12
STEP-12
Centering Of Install
Installbearings
bearings Final
FinalAssembly
Assembly
Turbine Foundation and
andRotors
Rotors

STEP-2
Setting of levelling Plates
and Levelling Wedges STEP-8
STEP-8 STEP-13
Provisional
Provisionalcentering
centering Grouting
Of
OfLP-1
LP-1&&LP-2
LP-2
STEP-3
Setting of Turbine
seatingPlates
STEP-9 STEP-14
STEP-9
Provisional Checking Final
Provisionalcentering
centeringofof
STEP-4
STEP-4 HIP Coupling alignment
HIP&&LP LP 11Rotor
Rotor
Installation
InstallationofofLP
LP And coupling
Outer casing
Outer casing

STEP-10
STEP-10
STEP-5
STEP-5
Installation
Installationofofinner
inner STEP-15
Installation
InstallationofofHIP
HIP
Parts of LP casing
Parts of LP casing Oil Flushing
Module
ModuleandandHP/IP
HP/IP
(Pre
(PreAssembly)
Assembly)
Pedestal
Pedestal

STEP-6
STEP-6 STEP-16
STEP-11
STEP-11 Final assembly of
Levelling
Levelling&&centering
centering 22 centering
ndnd
centeringofof HIP
HIP Pedestal Turning gear
Of
Of LP-1 andLP-2
LP-1 and LP-2 Turbine –LP Turbine
Turbine –LP Turbine & others
Casing
Casing

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 G-
n.

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 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.

MHI Turbine Generators

3D VIEW OF HIP PEDESTAL SEATING PLATE
& HIP PEDESTAL

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 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

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BEARING ALIGNMENT CURVE

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 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 Lift the inner lower casing and check
be properly welded level it should be equal in four
machine corner if not equal then make
equal by chain block.

MHI Turbine Generators

 Install Steam chamber
Install Inner casing carefully.

Install Blade Ring 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

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 Reamar bolt tightning

Lifting of inner casing

Lead Wire remove

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 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
Alignment Generators
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.

Adjusting
Adjusting Liner
Liner setting
setting Adjusting
Adjusting Liner
Liner Machining
Machining

MHI Turbine Generators

 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

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 Outer casing

Flow Guide inside OC Outer Casing installation

MHI Turbine Generators

 Step 12

Level Checking
Guide Pillar

Bolt Tightning

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 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=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.

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.

MHI Turbine Generators

MHI Turbine Generators