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(1)IM/07 (Restricted Circulation Only). POWER STATION ERECTION. CENTRAL TRAINING RESOURCES UNIT CORPORATE TRAINING DEPARTMENT.

(2) CONTENTS S. NO.. DESCRIPTION. PAGE NO.. 1.. Methods & Techniques used in Power Station Erection. 1. 2.. Methods and Techniques of Erection. 9. 3.. Erection of Boiler. 12. 4.. Boiler Drum Erection Procedure. 14. 5.. Steam Generator Package. 19. 6.. Erection of Boiler Auxiliaries. 21. 7.. Erection of Steam Turbine. 24. 8.. Boiler Feed Pump Erection. 43. 9.. Field Erection Procedure. 46. 10.. 500 MV Generator Erection. 61. 11.. Guidelines For Alignment of Rotating Machinery. 66. 12.. Hot and Cold Alignment. 74. 13.. Grouting of Machinery. 80. 14.. Erection, Alignment, Pre-Commissioning and Commissioning. 84. 15.. Precautions to be taken during Erection, Alignment & Grouting. 90. 16.. MW Tools and their Applications. 92. 17.. Effect of Misalignment. 99. 18.. Introduction to Alignment of Static Equipment. 102.

(3) 1. Methods & Techniques Used In Power Station Erection The Process of erection of a 500 MW unit is a very complex process. Work involved in the erection of a 500 MW unit are very large and the Techniques are so varied that it is quiet difficult to discuss them all in details. The following figures will give an idea of the work involved and are to be completed for the commissioning of one unit of 500 MW. 1.. Earth Work. approx. 10 lacs M3. 2.. Concreting Work. 1.1 lac M3. 3.. Structural erection. 120000 tons. 4.. Mechanical and Electrical equipments. 18000 tons. 5.. Length of piping. approx. 130 krns.. 6.. Length of cabling. 350 to 400 krns.. 7.. Brick work. 40,000 to 50,000 sq. mtrs.. Here we will discuss only the erection of major mechanical equipments and some of the important electrical equipments. To facilitate the discussion we can further sub divide the erection activities into specific areas such as. i). Structural. ii). Steam Generators & Auxiliaries. iii). Turbine and its auxiliaries. iv). Inter-connecting piping. © PMI, NTPC. 1.

(4) v). Special equipments such as boiler drum, generator stator and generator transformers.. vi). Miscellaneous piping and cabling. vii). Coal handling plant.. Since we have to cover the erection techniques and activities only \ we will not be discussing the techniques used for civil construction. This may be covered separately.. ORGANISATION Before we undertake any project work it is necessary to identify the requirements of manpower, define the organisational structure in which this manpower will work and then to clarify the role of each member of the team. In NTPC we have more or less standardised such requirements and the organisational structure. As you see the erection organisation at the project level is headed by a Additional General Manager. At the next level of the organisation it is divided into 2 Section Mechanical and Electrical each headed by DGM. Further sub division is done on equipment basis of specialisation for example we may have a Manager/Sr. Manager heading group responsible for the erection of turbo generator and auxiliaries and also have Dy. Manager who is responsible for welding and non destructive testing a very specific area of specialisation in the power house erection work. Similarly on the electrical side we have groups responsible for cabling 6.6KV switchgear and separate group for electrical testing.. ERECTION PLANNING AND SCHEDULING Before taking up such a large size work it is necessary to calculate and establish the inter relationship of the large number of erection activities to be completed so that the end result is achieved in a co-ordinated manner. The details of erection scheduling, are being covered separately, but we can discuss a broad relationship between major erection activities. As you will see that first activity to be started is the erection of power house structures, what we mean by power house structure is the turbine hall known as AB Bay. The equipment bay i.e. BC and the mill bay. This is followed by start of erection activities of steam generator structures, pressure parts and auxiliaries. After a time interval of 8 to 10 months follows the. © PMI, NTPC. 2.

(5) erection work of turbine, turbine auxiliaries and later on the inter - connecting piping. At about this time the erection activities on mechanical and electrical auxiliaries are taken up. This is a very broad based bar chart. In actual practice the entire activities are broken up package wise at three tier of planning and planning and monitoring. This detailing will be covered separately.. ERECTION EQUIPMENT Although hundreds of tools and plants are used for erection work. The major erection equipments now in use at the project sites are as follows.. Cranes We have 2 types of cranes available in the country - one type is tyre mounted and the 2nd type is crawler mounted. The tyre mounted cranes are generally in low capacity ranges, say, upto about 25 tons because of the limitation of the indigenous availability of tyres. The cranes above 25 ton capacity are all of crawler mounted type. In the higher range we have only 2 manufacturers in the country i.e M/s. Telco and M/s Hind Motors. The highest capacity crane is the 90 tons capacity no. 1055 BLC manufactured by Telco manufactured in India but now a days for 500MW Boiler, Froc Crane is used for structural work and ceiling Girder at capacity 285 MT on Ringer and 150 MT capacity cranes are also used. In the lower ranges i.e. upto about 25 tons capacity, a number of manufacturers have introduced cranes with hydraulically controlled collapsible boom. These hydraulic cranes are yet to prove themselves in the field and the manufacturing process has also to be established since so far the cranes supplied by these manufacturers have been only assembled in India.. Derrick This is perhaps the oldest fixture used for lifting of loads higher levels. The simplest derrick is the one used by workers for hoisting the electrical poles. However, the designing and fabrication of derrick has become sophisticated and at some of the projects derricks upto 200 tons capacity have been used for erecting heavy weight vessels.. © PMI, NTPC. 3.

(6) Winch A winch is nothing but a contraption to provide mechanical advantage. Hand winches upto about 1.5 ton capacity are still in use for small works but electric winches presently being used at project site may have as high capacity as 2500 tones. The limitation on size comes due to size of the rope and the rope drum, Electric winches are extensively used in combination with derrick for erection of mechanical and electrical equipments in a power house.. STRUCTURAL ERECTION The structures are either fabricated completely or partly at site and partly at the works of the contracting agency. In case part of the fabrication work is done at the works of the vendor pre-assembly work is done at site. In power house structures the main items are columns connecting beam trusses and the platforms. For a 500 MW unit the single columns lengths can be as much as 50 mtrs. and a single column may weight upto about 45 tons. The cross section through a typical power house indicating the location of the columns the height and approx. weight can be shown in the erection drawing.. The erection of the A & B row columns, can be done by using either a derrick or a mobile crane. The choice depends on the number of units to be done, for example, if only one unit is to be erected the use of crane becomes uneconomical as it calls for high initial investment. In such a case ordinary high capacity derricks are made use of. The columns may be lifted in a single pc., or in 2 pcs. depending upon the capacity of the derrick or the crane. The trusses which weight about 25 to 30 tons are lifted in single pc, after completing ground assembly, by using either 2 derricks or 2 cranes, two point lifting is preferred so as to avoid deformation during erection. Sometimes the physical position of the civil works may also necessitate the use of 2 cranes/ derricks.. The columns in the BC & D row have unnecessarily to be lifted in pcs. because of the length and the weight of single pc. This is necessitated because we do not have the cranes of adequate capacity to handle single column piece. As pointed out earlier the highest capacity crane manufactured is by Tata P&H is of 90 ton capacity at the minimum radium. The inter connecting tie beams are generally lifted one by one with the help of electric winches. This is. © PMI, NTPC. 4.

(7) a time consuming process but use of a crane for lifting the small weight beams and tracing works out to be uneconomical.. ERECTION OF STEAM GENERATOR The steam generator is the main and central equipment for the power house. It is also the most difficult and complicated from the erection point of view. A 500MW steam generator means an assembly of approx. 80,000 to 90,000 different sub-assemblies adding upto a sizable 24,000 tons of equipments. The equipments may be as rough as structures going up in sophistication of a furnace control cubical. The erection starts with the positioning of boiler structures. Since the height of the column may be as much as 90 mtrs., with the single column weight may be 100-110 tons. The use of higher capacity crane is essential. However, the structures can also be erected using a set of 2 high capacity derrick in case only one unit is to be done since the deployment of heavy capacity crane for one unit alone will call for high investment. The erection of the pressure parts systems follows the erection of structures this is a sophisticated work from the view point of technology of welding. For a 500 MW steam generator as many as 25,000 high pressure, welds have to be made at site, radiographed and tested at high pressure, before the steam generator declared ready for light up. High technology proccsass are used to ensure quality welding since failure of a single weld will result in the shut down of unit resulting in heavy loss in generation. As pointed out earlier the erection time span is about 48 months requiring deployment of 600 to 800 persons and of sophisticated high capacity erection equipment.. TURBINE AND ACCESSORIES The 500 MW turbine is in 3 parts i.e. low pressure, intermediate pressure and high pressure casing. For the thermal stations in India we have 2 types of turbines under operation and erection. The units installed till 1982 mostly have turbines of Russian design and whereas German design of M/s KWU has been used for stations installed after 1982. From erection point of view both these turbines are very much different from each other. In case of Russian designs complete assembly has to be done at site for all the 3 casing, where as in case of KWU turbines IP casing and LP casing are assembled at site and other 1 casing are completely shop assembled. However, in both the designs the condensers is completely assembled at site.. © PMI, NTPC. 5.

(8) The erections are generally started with the assembly of the conde nser either in site or out side the turbine hall. After completing the assembly of the shell, it is aligned and leveled in position and then the turbine work is started. This process takes about four months. The erection of the turbine is started with the placement of LP casing followed by IP and HP when the work on the main turbine is going on simile tenuously the erection of auxiliary system like oil system cooling system auxiliary steam system etc. starts. After the turbine is boxed up the final connection of the auxiliary systems are made and thereafter the work on instrumentation is taken up to make the turbine ready for starting the pre-commissioning tests in the unit.. INTER CONNECTED PIPING There are many many piping systems connecting the main equipment of steam generator and turbo-generator and these main equipments to the auxiliary systems. These piping system carry water, air, condensate, steam etc. from one point to another point as per the flow diagrams. Although there is no work of heavy lifting as the piping pcs. are of prefabricated lengths and have such weights which can be erected with the use of electric winches. There is extensive work of welding, stress relieving and non destructive testing a special induction heating m/c is used for X-20 material (High thickness) pipe joints. The normal process followed in erection of piping systems is to lift them to position piece by piece place them on temporary supports, level and align maintaining suitable slopes, and then carry out the welding. After completing the welding the permanent supports and hangers are installed, adjusted and the piping load is released. The systems are then hydraulically tested to supplement the non destructive testing and also to specify the statutory requirements. After the completion of these stages some of the piping systems are insulated depending upon the service conditions. Erection of valves is the one which needs close attention. If the valves are not properly erected they can cause very serious operation problems. The valves should be completely serviced before erection, they are to be installed in the correct direction of flow and it should be seen that they are accessible for operation. Each valve should have tag no. properly identified and direction of opening and closing normally marked on the hand wheel with suitable platform for access.. © PMI, NTPC. 6.

(9) ERECTION OF SPECIAL EQUIPMENTS There are 3 critical equipments in the power house erection. They are boiler drum, generator stator and generator transformers. We will briefly discuss the erection of these 3 equipments.. Boiler drum For 500 MW unit BHEL design the boiler drum is about 24.5 meter long has a diameter of 2.2 mtrs. and weight approx. 234 tons. This heavy mass has to be hoisted to a height of 22.5 mtrs. on the front side of the boiler and is to be suspended from the roof beams. For the erection of boiler drum, a temporary structure is erected on top of the boiler structures and 2 sets of pulley blocks of 150 tons capacity each are hoisted from this structure. A similar set of pulleys is tied to the boiler drum and a steel rope of 25mm & 23mm dia is taken to four electric winches each of 15 & 10 tons (2 each) capacity. This arrangement is sufficient for lifting a 300 tons load (boiler drum is weighing 247 tons). The extra provision in lifting capacity is to be made to absorb shock loading during lifting of the boiler drum.. Generator Stator This piece of equipment, to be installe d on the turbine floor, weight about 265 tons has a dia of approx. 4 mtrs. and a length of 8.5 mtr. depending upon the power house design and lay out the stator may be lifted by portal cranes temporarily errected in turbine hall. In some of the power stations another method has been used by which the stator has been placed on the turbine floor using a temporary gantry crane. Under this arrangement, a gantry crane is placed over the structures which lifts the stator placed directly under its hook, moves to the actual position of the stator and stator is lowered on to the foundation. This is a simpler and less costly method and has now been adopted for our 500 MW unit under erection.. Generator Transformer This transformer again is in the region of 130 tons weight, is about 4.5 mtrs. high and 10 to 11 mtr. long. This is erected on the outside of the turbine hall on a row side and is to be placed on foundation which has got embedded rails. Normally the transformer is literally dragged to position by the use of a set of rollers and the rollers are then tied to the. © PMI, NTPC. 7.

(10) foundation franc of the transformer. Occasionally used of heavy duty mobile cranes has to be made where there are problems of access to the foundation. Although the erection activity is simple, extensive work has to be done after the transformer has been placed. After placement of the transformer on the foundation the work on the other auxiliaries such as cooling system, oil system and fire protection system is take up.. TECHNICAL CHECKS DURING ERECTION Proper erection of any equipment plays a vital role in the ultimate performance of that equipment and the system as a whole. It has been observed that even an equipment which has been very well designed, manufactured under strict quality control can be a failure in operation if it is not correctly erected. This important aspect must be clearly understood by those who want to make a career in erection. Unfortunately this aspect of the work has not got the proper attention it needs and it is wrongly thought in may organizations that erection is any body’s job, but it is not so.. To ensure proper, quality of erection work, a system of check and measures must be developed, check lists for the proper logging of the completion of stages of erection should be. developed. in. consultation. with. the. suppliers.. These. check. lists. should be verified by an independent agency such as field quality assurance group at site. Various techniques are being used at site for checking the quality of welding, which is a very important aspect of field work. The methods are:. i). Dye penetration test. ii). Radiography. iii). Ultrasonic testing.. The results of all these tests have to properly recorded and preserved for approval by the boiler inspector of the state where the unit is being installed.. © PMI, NTPC. 8.

(11) 2. Methods & Techniques Of Erection Methods & techniques for certain part of erection activities are commonly applied whereas for certain equipment exclusive in nature, erection personnel are required to be educated thoroughly before proceeding with the erection. In fact the erection activity is very broad in nature and does cover some peripheral activities which are not directly connected with actual erection job but are desirable in order to have a systematic output. These activities along with the erection activities are tabulated in the sequence it is required to be followed.. 1.. TRANSPORTATION, INSPECTION & STORAGE. This activity forms the input for next activity. Once the material is received at site all parts are checked with the help of packing list 1\2 slip sent with the consignment and relevant drawing if necessary. Missing\shortage\damaged items are listed under respective heads and action is taken to replenish\repair the same. Nearly 30,000MT, materials are installed in one unit at 500 MW Boiler. After inspection is carried out, the components received are stored/stocked properly in order so that their life is not reduced due to prolonged storage and retrieval at the time of requirement is also easy. Long storage is done with specific preservation methods which is time dependent. Storing may be done outside or inside depending on the nature of the component. Preservation methods which are commonly adopted are, a). Rust Preventive. b). Corrosion inhibitor. c). Sillicagel application. d). Spray reel application etc.. © PMI, NTPC. 9.

(12) 2.. PREPARATION FOR ERECTION. The following details shall be thoroughly studied with the individual contracts reg. size, range application, and scope of supply with reference to the product offered. Preparation for erection:. i). System lay out. ii). Assembly drugs. of various equipment. iii). Performance drugs/manuals. iv). Installation drawings. v). Foundation plans. vi). Scope of supply of the contracts. vi). Scope of supply of the contracts. vii). Shipping lists with respect to erection drawings. After ensuring the above, following are to be observed. 1). Before proceeding with erection adequate arrangements for safe handling of equipment is to be made at work site. This may include tools, tackles rigging and handling facilities required for erection. Special attention is to be paid for the shape/size/wt. of the components as well as the space limitations while proceeding with installation.. 2). In line with the construction management philosophy erection department is required to be actively involved in the checking of foundation before it is cast and after it is cast for any defects which maybe detrimental for the equipment. Performance in the longrun as well as cause difficulty during the course of erection.. © PMI, NTPC. 10.

(13) This is achieved by paying special attention to the dimension of the foundations to be cast by keeping a close touch with the civil department. Also after casing of foundation it is checked immediately for any abnormality as regards centre line shift and other mistakes. 3). The material received earlier at stores and stocked properly are to be retrieved as per the sequence of erection to be done with ref. to drawings/manuals etc.. 4). The preservatives used during storage purposes are to be cleaned thoroughly and the item be made ready for assembly/erection.. 5). Finally foundations is taken over with all respective dimensions properly checked with limits / tolerance specified in the drawing. Attention should be paid to presence of match marks for components. For large components which require pre-assembly separate area is identified where such activities can be carried out. After pre-assembly the components are transported with care to the foundation for erection.. 6). For placing any equipment/column structure on the foundation a base plate is first erected on to the foundation on packing plates which takes care of matching of base plate with the foundation as well as for alignment of the equipment/column structure.. This matching is achieved by matching the pack or plates or blue matching as may be the level of requirement. 7). Once the first part of the equipment is erected and leveled / aligned, the equipment is grouted i.e. the space below the base plate and the foundation is filled with suitable grout mixture to have a compact filling with good bounding with the foundation.. 8). The next step is to go ahead with further erection as per the standard erection procedure as laid out and as per the sequence predicted boiler drum lifting is given as a typical example.. © PMI, NTPC. 11.

(14) 3. Erection Of Boiler The following will illustrate a brief outline on boiler erection emphasising on the key technical requirements to be fulfilled. As stated earlier, having assimilated the assembly drawings, detail drgs, bill of materials, quality documents and other relevant information sequence, stepwise erection activity is taken up.. 1.. COLUMN ERECTION. The boiler presently in use are hanging type i.e . these are supported at the top in order to allow free expansion of the boiler during hot condition without any hinderance whatsoever. However the anchor point called ceiling girder on the top of the boiler is adequately structured on top of support columns called ceiling girder on all the sides of the boiler so that the load transfer could take palce to the foundations. Hence the importance of columns is immense.. In order to have a strong and safe structural footing, the columns are to be erected very carefully. Since the columns are very tall it can not be transported and erected in one piece. So the columns are broken up during manufacture into several pieces and transported to site where it is pre-assembled in two or three pieces and erected. Now a days Pre-assembly is being done in shop & column design has changed from (H) section to (T) section. Utmost care is taken in the pre-assembly stage to maintain the matching of the column end faces and to achieve a verticality well within the tolerance limits prescribed. Verticality is the single most important factor and is given top priority as the columns are vertical and a small error at the base level may reflects a severe inclination at the top which is dangerous from loading the columns with associated boiler component. This is achieved by ensuring verticality at every level of the column and by bracing the columns with another in order to reduce the slenderness of the columns as a single piece. The column vertically is allowed 1 mm/metre & max. of 20 mm.. Once the column erection is. over up to the full height, the cross beams are placed securely over the columns which support the main boiler. In order to carry out this job special erection tools like cranes with extra long boom to carry heavy loads at that height are deployed.. © PMI, NTPC. 12.

(15) When this cross beam erection is over the entire structure so erected is adequately braced so that sufficient rigidity and strength is obtained for further loading these structures by erecting the boiler drum, headers and subsequently the pressure parts. Nearly 46000 (HSFG) High strength friction bolt are used for erection & to strengthen the main structure.. 2.. PRESSURE PARTS. The pressure parts are composed of headers which are having numbers stubs welded on to it on one plane and collector pipe stubs (relatively larger in size) on the other plane, or on the same plane depending on the requirement. After these headers are supported from the overhead beams the water wall panel erection is taken up. These panels are tubes joined in one plane by fusion welding up to a required length. One side of boiler water wall may require 35 to 40 such panels to be welded with one another. During the formation of these boiler walls with panels the verticality of the wall and its axis with respect to boiler centreline marked earlier with reference to drum position is maintained. The walls so erected are temporarily supported with the structure in a continuous manner. After the four walls are completed alongwith their bottom headers in position the furnace is floated i.e. the temporary supports are cut and removed so that the entire load of the furnace is passed on to the support hangers at the top. Subsequent to this the axis of the furnace is checked for the shift and corrected if required. The hangers which has been loaded with the furnace are then checked individually for its proper loading. In order to avoid differential loading the hangers are adjusted to their required value. Total Boiler pressure parts is divided in two passes name as First Pass, Second pass & weight of pressure parts are nearly 5,000 MT.. 3.. MISCELLANEOUS. After the erection of pressure parts is over other erection activities; like, insulation, soot blowers, and other peripheral activities connected with the boiler light up is taken up alongwith the above jobs. The finishing activities of the boiler is taken up with an emphasis on the safety and operational aspects. This is most important.. © PMI, NTPC. 13.

(16) 4. Boiler Drum Erection Procedure Procedure 2X500 MW STEAM GENERATOR ERECTION 1.. INTRODUCTION. Boiler drum lifting is one of the milestone in 500 MW Boiler Erection. In fact after 1st column erection the time given is 9 months, during which 3600 MT structural erection is to be completed for activity. This includes Main Columns, Aux. Columns, all Bracing upto level, Ceiling Girders, Welded Beams & Rolled Beams.. The Auxiliary preparation work for drum lifting includes welding of cat head structure at the roof level, making ready of winches with anchoring arrangements, fixing of main pulleys, auxiliary pulleys and guide pulleys. Here we will discuss about the salient features of drum and its lifting procedure.. 2.. TECHNICAL DETAILS. a). Drum i). Over all length. :. 24216 mm. ii). Size (Bithikness). :. R 874 x 195, R 889 x 165. iii). Weight (without internals). :. 234 MT. iv). Elevation (drum centre). :. 72508 mm. v). Distance from girder B. :. 6257 mm. vi). No. of lifting lungs. :. 2 (for stage I lifting) 2 (for stage II lifting). © PMI, NTPC. 14.

(17) b). Suspension Rod i). No. of Suspension rod. :. 2. (U type). c). ii). Over all height. :. 13518.5 mm. iii). Weight (2 Nos.). :. 14 MT. iv). Dist. between U-rod arms. :. 2350 mm. v). Dist. between U-rod. :. 13412. :. Between A&B Girder on. Supporting Structure for drum i). Location of drum Suspension beam. ii). Elevation of drum. WB3 & WB4 :. 83155 mm. :. 26000mm. Suspension iii). Centre line distance of side column (S7L to S7R). 3.. SALIENT FEATURES. Since the Boiler Drum length 24216 is within the clearance available between two columns 26000 mm; the drum had to be lifted in horizontal position.. Also, since the column S14L & S14R has to be erected and all interconnections completed upto 68 M, the drum has to be lifted initially at a height of 68 M from front row of columns between SSLR & S9LR.. After crossing the structure at 68 M, the drum has to be shifted to the final position (i.e 2993 mm from front row of columns).. © PMI, NTPC. 15.

(18) 4.. LIFTING ARRANGEMENT. The equipments required for drum lifting purpose has been given in a separately for reference. The pulley blocks are approximately 700 mm wide & 1700 mm in length and the distance between the lifting lugs provided on the drum is only 915 mm since both the pulleys have to be attached to the drum, the lugs on the drum for stage I & Stage II lifting are kept at right angle to each other:. The pins used on drum lugs are of 512 mm and those used with pulley block are of 225 mm.. ROUTING THE ROPES THROUGH GUIDE PULLEYS All four winches of 15 T & 10 T are positioned between Boiler & ESP. The first guide pulley of the 15T will be attached to the Wbs at the ceiling and the rope is to be brought down to 515 columns base and then to the 15T winch. The first guide pulley of l0T will be attached to Wbs at the side blacing in column 510 at 79.9 Mtr. and it comes to 10T winch to 516 column.. ANCHORING OF WINCHES All the winches are placed on a plain wooden mat then anchored to Tower crane parking block concrete blocks. After the load test of all winches, interconnection is done between all the 4 winches to minimise vibration and dislocation during operation. Suitable guide pulleys with pulling M/ C are to be arranged for guiding the rope winding on winch drums.. © PMI, NTPC. 16.

(19) AUXILIARY WINCHES & ITS CONNECTIONS The first set of rigs (15T) are attached to the drum at ground level and the second set of the rigs (10T) will be brought upto 68 Mtr. and temporarily anchored at this level. 3 ton winches are attached to the (10T) rigs for holding the bottom pulley blocks to facilitate attachment to the drum at 68 M before Stage II Lifting.. The U-Rods will be kept lashed on to the boiler drum in slanted position. The distance between the U-Rod ends is to be maintained by attaching channels bol ted on either end. 5T winch is employed along with 2 sheave pulley blocks for lifting either of the U-rods after the drum reaches its final position. The top guide pulleys will be anchored on to a temporary beam kept on top of drum suspension beams.. MISCELLANEOUS The Boiler Drum (with U-rods lashed on) is to-be lifted 1 mtr. initially and pulley block and guide pulley are checked for proper orientation and to ensure smooth passing of ropes. Also the structural members are to be checked for any possible deformations.. The Drum is allowed to remain in this position for approx. half an hour to verify the break hold of winches.. LIFTING 1.. The drum is brought between column no. 8LR & 9LR and then it is lifted uniformly until it reaches 68Mtr. with the 1st set of pulleys and using 15T winches.. 2.. There upon the 10T second set of rings are to be attached to the drum lifting lugs. 10T winches operated for keeping the rope fully taut. Afterwards the first ring (15T) is to be gradually released so as to allow the drum to drift towards final position after the first stage pulley are released (by 15T winches), the second stage of pulleys are tightened (10T winches) for maintaining the drum centre elevation approx. 73 M.. © PMI, NTPC. 17.

(20) 3.. The U-rods lifting pulleys are attached at this stage, to either of the U-rods and then U-rods are made vertical and gradually lifted to the required height. After the U-rods passing through the holes of the rocker plate, nuts are screwed until the projected length is maintained. At this stage, the U-rods bottom is held by rope so as to ensure that the U-Rod is properly placed at the distance of 13.412 mm and also that the U-rods are on the inner of the stopper lugs.. Thus after ensuring that all four lugs of U-rods are properly positioned and nuts tightened keeping the required projection. The drum is to be gradually lowered on to the rods until the wire rope is slack and load is transferred on the U-rod.. 4.. The level of the drum centre is to be verified by water level at this stage to ensure exact elevation 72.508 M + 3mm.. © PMI, NTPC. 18.

(21) 5. Steam Generator Package 1.. T & P REQUIRED FOR DRUM LIFTING (500MW). WINCHES S.No. Item. Qty.. Remark. 1.. 2 Nos.. For stage I lifting. 2 Nos.. For Stage II lifting. 2 Nos.. For ‘U’ Rod lifting. 2 Nos.. For side pulling of drum at 70 M. Electric winch of 15T cap with wire rope 28 mm; 2800 Mtr.. 2.. Electric winch of 10 T cap. with wire rope 26 mm; 1200 Mtr.. 3.. Electric winch of 5 T cap. with wire rope of 1”. 4.. -do-. Level 5.. Electric winch of 3T cap with. 2 Nos.. 3/4” or 7/8” rope. Pulling stage II lifting pullies for conn. with drum before stage II Lifting. PULLEYS 1.. 300 T - 15 shieve pulley block. 2 sets. For Stage I lifting. (4Nos.). 2.. 300 T-15. -do-. 2 sets For Stage II lifting. (4 Nos.). 3.. 30 T - single shieve pulley (Guide). 12 Nos.. For guide pulleys in Stage I & II lifting.. © PMI, NTPC. 19.

(22) 4.. 10T - 2 shieve pulley block. 4 Nos.. ‘U’ Rod lifting. 5.. 50/40 T-3 shieve pulley. 2 Nos.. For side pulling of drum block (with 5-2 Col.). 6.. 25/30 T - 2 shieve pulley. 2 Nos.. -do Block (withS-I col.). 7.. 10T-2 shieve pulley block. 4 Nos.. For pulling the bottom pulley of Stage II lifting towards rear. 8.. 5T chain pulley block. 2 Nos.. For alignment of Stage II lifting pulley block while inserting the pin with drum lug.. 9.. D-shackles dog clamps of various sizes for the above. MISCELLANEOUS 1.. Walkie - Talkie. 2.. Telephone at ‘O’ M & 72 M.. 3:. Colour flags & whistles. 4.. Flood, light arrangements.. 5.. Cameras & video camara etc.. © PMI, NTPC. 20.

(23) 6. Erection Of Boiler Auxiliaries Among the auxiliaries which require utmost care during erection are Fans, Mills and Air Pre heaters. Only one case of fan will be dealt which itself will be sufficient to envisage the complex nature of the activity and carefulness to be adopted during erection stage. In general, the same technique will be applied for other rotating machines also.. 1.. INSTALLATION OF BASE PLATE As discussed elsewhere the correctness of foundation in case of rotating machines is very important. Once the correctness of the foundation has been ensured the foundation bolts of the equipment is mounted in the pockets made in the foundation for the purpose. The locking of the foundation bolts with anchor provided inside the foundation is ensured thereafter.. 2.. GROUTING After the locking has been achieved, grouting of the pockets is to be done with a suitable grouting mixture either by preparing at site or readily purchasing from the market. Once the grout is set the packers are set into their position by blue matching the surface in contact to ensure proper contact for effective load transfer. The base plate is then placed on the packers and the bolts temporarily tightened and relative elevation of the base plate at different locations is observed by employing a water level gauge, straight edge etc. Each base plate is leveled to the required accuracy along and perpendicular to the fan axis. To achieve this, micro adjustment stainless steel shims of various thickness are used.. 3.. MAIN FAN ERECTION The impeller and the other related housings diffusers are then placed on the foundation base plate. These are then aligned with the centre line of the foundation. The elevation as per the requirement is also ensured. The important alignment. © PMI, NTPC. 21.

(24) parameter to be checked and maintained at this stage is the verticality of the impeller or the horizontality of the shaft. This is achieved with a master level gauge and it should be within O.4mm/M. The above exercise is to be carried out by tightening all the foundation bolts properly so as to avoid any stress induction in parts due to physical distortion.. 4.. MOUNTING OF COUPLING The shaft end and coupling bore dimension are measured and recor ded and then should comply with the product drgs. The coupling is shrunk fit on to the shaft. In order to mount the coupling it is heated in a oil bath by maintaining a temperature of 150 0 C approx. in the bath.. 5.. ASSEMBLY OF IMPELLER BLADES The blades of each impeller are identified by an alphabet series alongwith a serial number. One such set of blades (for axial fans only) are taken and mounted on to the impeller hub starting from any one location and proceeding in the serial order as market on the blades and these may be done in clockwise or anti clockwise direction as found convenient.. 6.. INSTALLATION OF MOTOR As applicable for the fan erection, the motor has to be erected on the base frame and then aligned with respect to the fan. This is necessary as the fan housing is rarely removed from position and hence it may be considered as fixed. Whereas the motor is removed as a total unit several times for maintenance purposes.. 7.. ALIGNMENT The alignment of one equipment with respect to the other is very important. For carrying out the alignment job, precision tools are required. Dial gauges of least count of 0.001mm is required. These instruments are mounted on both the ends of the shaft connecting the equipment and the shaft is rotated. The rotation of the shaft. © PMI, NTPC. 22.

(25) gives the misalignment reading at various angular position of the shaft which later is corrected by adjusting the motor on the base frame.. 8.. INSTALLATION OF OTHER MISCELLANEOUS EQUIPMENTS The fans, air preheaters, mills will necessary require a lubrication system which may be internally mounted or externally mounted. For externally mounted lub oil system unit certain precaution is to be observed while erection. As the oil supplied by the oil unit is directly going to the bearings so the oil should be totally clean. The oil piping which is connected to the fan with the oil unit is cleaned thoroughly by acid to remove rust and scales, then washed with caustic soda and finally preserved with oil and installed thereafter.. 9.. GENERAL While the erection of rotating machines are in progress cleanliness of the internals of the equipment is to be ensured. Running clearances required as per the documents is to be documented properly in the format supplied. This is the history card of the fan and will be the base document for future reference.. The applicability of the requirements what has been discussed may vary with the type of equipment supplied but in general the principle adopted is similar.. I.D. FAN A special type of I.D. fan installation is being started with V.F.D (variable frequency drive) arrangement where ID fan started with zero speed & picks up the speed as per requirement of system.. © PMI, NTPC. 23.

(26) 7. Erection Of A Steam Turbine Of the various types of prime movers available today viz. Electric motors, Steam turbines and gas turbines, steam turbine is widely used in Chemical, Petro-chemical, power, fertiliser, and other industries owing to its low cost of operation and dependability.. AUXILIARY UNITS Normally steam turbines will consist of a lub oil circulating unit, gland steam condenser and vaccum pumps, a condenser and condensate pump are the other units if it is a condensing type of turbine.. COMPONENTS OF A TYPICAL STEAM TURBINE The following are the important components of a typical turbine. 1.. Turbine Casing (in two halves).. 2.. Diaphram & nozzles.. 3.. Rotor.. 4.. Journal Bearing.. 5.. Thrust Bearing.. 6.. Governor.. Erection Like any other equipment care should be taken regarding the orientation and elevation of the turbine. It is needless to say that precautions taken for a rotary equipment should be taken for a steam turbine also.. © PMI, NTPC. 24.

(27) We can divide the erection into various activities listed below:1.. Initial leveling.. 2.. Pocket grouting. 3.. Tightening of anchor bolts and re-leveling.. 4.. Final grouting.. 5.. Centering the rotor and leveling.. 1.. Initial Levelling The machined levelling surfaces provided on the base frame are used for this purpose. Usually the initial levelling is done either on the jack bolts or on the liner plates, within tolerance specified by the manufacturer.. 2.. Pocket Grouting. Either epoxy materials or any non shrinking grout is used for grouting the machinery. Care should be taken to keep the anchor bolts vertical at the centre of the hole during the grouting. 3.. Tightening the Anchor Bolts and Relevelling After the grout is sufficiently cured, the anchor bolts are tightened and the level is checked again with master levels. If there is any deviation it is relevelled shimming between the sole plate and the liners.. 4.. Final Grouting. Once this is accomplished the equipment is released from the jack bolts and loaded on the liners. While carrying the final grouting under the base frame care should be taken to avoid air getting trapped. Some manufacturers ask for a recheck in the level. © PMI, NTPC. 25.

(28) after the grout is cured to detect any change in level due to the shrinkage of the grout.. 5.. Centering the Rotor and Levelling After the equipment is grouted the clearances between various components are checked and the results are compared with that obtained at shop. They are: 1.. Clearance between the rotor and the casing.. 2.. Clearance between the rotor and the bearing. 3.. Clearance between the rotor and the seal.. 4.. Rotor level.. 5.. Lateral position of the rotor which respect to the thrust bearing.. If the shop values are different from the site values, the rotor is then centered again as per the protocol. 1.. Casing Centering. A dial gauge is mounted on the rotor with the plunger touching the surface of the casing near the seal axially. The rotor is then rotated and dial gauge reading noted at 3 0’ clock 6 0’ clock and 12 0’ clock position. If the readings are not the same as the shop values then the rotor is lifted with the help of jack bolts and the casing shifted by jack screws. The movement is monitored by fixing dial gauges.. 2.. Bearing Housing Centering and checking the lateral position of the rotor Centering of the rotor with respect to the bearing housing and position of the rotor with respect to the thrust bearing are two vital points to be taken care of.. © PMI, NTPC. 26.

(29) The gap between the thrust collars on the rotor and the thrust bearing is measured and the position is set with the help of jack screws. After the lateral position of the rotor is fixed, the journal bearing is removed and two dial gauges are fixed on rotor. At both the active and inactive side. The readings are noted at 3 O’ clock, 6 O’clock and 9 O’clock positions. The bearing housing is shifted with the help of jack screws if there is any change in the readings. Sometimes the clearance between the bearing and rotor is checked with the help of a lead wire. In this case the top half of the bearing is opened and a thin lead wire placed on the shaft. The bearing is replaced then and tightened. It is reopened again and by measuring the thickness of the leadwire the clearance is measured.. 3.. Rotor Levelling The rotor should be at a redetermined level depending upon the cut of various blades mounted on it. This is checked with the help of a master level and any change from the shop value is corrected. After all these exercises are completed the machine is said to be initially aligned. Then various piping connections are given without introduction any strain in the system which will affect the level of the equipment to a very greater extent. All the flange connections should be parallel to each other and all the pipes are to be properly supported. We carry out these centering checks once again after all the piping connections are made to find out whether these have introduced any strain on the machine. Any adverse change leads to the rectification and re-work of turbine.. © PMI, NTPC. 27.

(30) TURBO GENERATOR 3X500 MW Erection activities of TG are classified into the following main categories: 1.. Condenser. + LP heater No. - 1. 2.. Turbine. i). HP Turbine. ii). IP Turbine. iii). LP Turbine. iv). HP & IP stop cut control valves. i). Generator. ii). Excitor. iii). Terminal Bushings. iv). H2 coolers. v). Excitor coolers. i). Lub oil equipment (oil tank, aux. oil. 3.. 4.. Generator. Auxiliaries a) Turbine pumps, coolers,. jacking oil. oil. pumps,. centrifuge,. oil. vapor. exhausters, & Duplex oil filter). ii). Control fluid equipment (CF tank, CF pumps,. Mechanical. filters,. Earth. filters, Accumulators, supply units). iii). Governing Rack. iv). LP by pass Rack. v). Condenser on load tube cleaning system.. vi). © PMI, NTPC. Vacuum pumps. 28.

(31) vii). HP by pass system. i). Stator water unit. ii). Seal oil unit. iii). Gas system. iv). Excitation equipment. i). UCB. ii). Relay & Turbovisory panels. iii). Local JBs and instruments. iv). Cabling.. i). Main steam piping. ii). Hot Reheat piping. iii). Cold Reheat piping. iv). LP bypass piping. v). TG cycle drains. i). Lub oil piping. ii). Control fluid piping. b) Generator. 5.. 6.. Control & Instrumentation. Piping a) Critical Piping. b) Turbine Integral piping. © PMI, NTPC. 29.

(32) iii). Gland steam piping. iv). Condenser Air Evacuation. v). TG drains. i). Seal oil piping. ii). Stator water piping. iii). H2 gas piping. i). Condenser cooling water. c) Generator Integral piping. d) External piping piping. 7.. Interface. ii). Aux. cooling water lines.. i). Foundation checking for all equipment. ii). Terminal points take over/ hand over.. 8.. Customer Inputs. © PMI, NTPC. iii). Electrical checks interface. iv). C&I interface. i). Safety Inputs. ii). Civil foundations. iii). Floors, ‘O’ M, 8.5 M & 17.0 M. iv). Approaches. 30.

(33) v). Lighting. vi). EOT cranes. vii). Power Supply. viii). All associated pkgs. required for synchronisation and running of the units.. ix). Construction Power. that. it. CONDENSER ERECTION 1.. Inspect. foundation. and. check. conforms. to. the. drawing.. (Level, dimensions, pockets, identify longitudinal & transverse centre lines.). 2.. Place on the foundation spring elements the springs are placed in locked condition with heights adjusted to give the required slope.. 3.. Pre-fabricate/assemble condenser bottom plate and hot well.. 4.. Place bottom plate with hot well on springs.. 5.. Pre-fabricate side walls.. 6.. Pre-fabricate water box tube plates.. 7.. Place tube plate and side plates on the bottom plate, align and weld.. 8.. Pre-fabricate Dome walls.. 9.. Install tube support plates & weld.. 10.. Install stiffening structure, air evacuation zone.. © PMI, NTPC. 31.

(34) 11.. Install Dome walls and LP Heater 1 supporting structure.. 12.. Install LP Heater No.1. 13.. Clean condenser steam space.. 14.. Insert condenser tubes and expand.. 15.. Weld condenser neck (dome walls) with LP Turbine exhaust hood.. 16.. Hydro test of condenser steam space and leak test, & drain.. 17.. Assemble water box covers and hinge assembly.. 18.. Hydro test water side.. 19.. Release condenser springs and adjust to operating valves.. 20.. Drain water box and remove hydro test flanges.. Note: PROTOCOLS ARE TO BE MADE AS PER THE FIELD QUALITY PLAN. L. P. TURBINE - ENSURE SAFE WORKING CONDITION 1.. Check and prepare foundation w.r.t. drawing and plant bench marks and identify long and transverse centre lines.. 2.. Place and level LP outer casing base plates, IP and LP rear bearing base plates and grout with non shrink cement.. 3.. Install LP longitudinal girders, and LP casing lower front and rear walls.. 4.. Install longitudinal fixed points for front and rear walls.. 5.. Place LP inner casing lower half section and make preliminary alignment.. © PMI, NTPC. 32.

(35) 6.. Place lower half of divisor sections.. 7.. Place LP inner casing upper half and the diffuser sections and align.. 8.. Assemble LP outer casing and weld match the parting planes.. 9.. Remove LP outer casing and inner casing upper half and prepare LP rotor for placement.. 10.. Place LP rotor and do final alignment of LP in casing and shaft seals.. 11.. Fix axial and radial keys of LP outer casing.. 12.. Weld internal piping of LP casing.. 13.. Checks steam flow path clearances.. 14.. Box up, LP inter casing and outer casing.. 15.. At this stage it is expected that HPT and IPT are erected and aligned w.r.t. LPT.. 16.. Centre LP glands and install compensator.. 17.. Install seal rings for hearing casing and align.. 18.. Prepare pedestals for OIL flushing.. Note: PROTOCOLS ARE TO BE MADE AS PER THE FIELD QUALITY PLAN.. I. P. TURBINE - ENSURE SAFE WORKING CONDITION 1.. Along with the placement of pedestals of IP rear and LP rear bearings the remaining IP front and HP front bearing pedestals sole plates are also erected, levelled.. 2.. Respective pedestals are placed on position and aligned w.r.t. turbine centre line and transverse axes.. © PMI, NTPC. 33.

(36) 3.. Pedestals are then grouted.. 4.. Cleaning and preparation of lP turbine for erection.. 5.. Place IPT in position, centre and level it.. 6.. Align IP rotor with LP rotor.. 7.. Fix IP front bearing position axially.. 8.. Final centering of IP casing.. 9.. Rolling test.. 10.. Honing of coupling bolts of IP and LP rotors.. 11.. Cross around piping from IP to LP turbine is parallel done.. 12.. Erection of barring gear.. Note: PROTOCOLS ARE TO BE MADE AS PER THE FIELD QUALITY PLAN. H.P. TURBINE - ENSURE SAFE WORKING CONDITION 1.. Prepare HP turbine for erection.. 2.. Place HP turbine in position, centre and level it.. 3.. Aalign HP rotor with IP rotor.. 4.. Final centering of HPT.. 5.. Align main oil pump with HP rotor.. 6.. Rolling test.. © PMI, NTPC. 34.

(37) 7.. Honing of coupling bolts of HP and IP rotors.. 8.. Final alignment of HPT, IPT &. LPT with respect to the coupled rotor.. 9.. Carry out horn drop test of HPT and IPT.. 10.. Check final oil clearance of bearings and box up bearing pedestals. This applies to all the bearings of HPT, IPT & LPT.. 11. Prepare for oil flushing.. 12.. Oil flushing.. 13.. After completion of oil flushing normalise bearings and box up.. 14.. Insulate HPT & IPT.. Note: PROTOCOLS ARE TO BE MADE AS PER THE FIELD QUALITY PLAN. STOP CUM CONTROL VALVE ENSURE SAFE WORKING CONDITION 1.. Check elevation and centre lines for the structure at 17M floor on which the suspension frames for stop cum CVs are to be placed.. 2.. Place suspension frames on the structure and blue match it.. 3.. Remove the suspension frames and attach valve suspensions to the frames.. 4.. Prepare the stop cum CVs for erection.. 5.. Lower the frame with suspensions over the valves and assemble the valves to the suspension.. 6.. Install the complete assembly on the structure and fasten it.. 7.. Level the stop cum CV in x,y & z directions by means of tie-rods in the suspensions.. © PMI, NTPC. 35.

(38) 8.. Repeat the procedure for 4 Nos. HP valves and 4 Nos. IP valves. 9.. Procedure is more or less similar for LP bypass valves (2 Nos.). Note: PROTOCOLS ARE TO BE MADE AS PER THE FIELD QUALITY PLAN. GENERATOR - ENSURE SAFE WORKING CONDITION 1.. Check foundation and make logitudinal and transverse centre line. Check levels w.r.t. bench mark.. 2.. Place cross beams and mount terminal box.. 3.. Place pedestals sole plates, level and grout.. 4.. Check pedestals for PORTAL CRANE.. 5.. Install and commission portal crane, along with load testing.. 6.. Place the generator stator special wagon with the stator adjacent to the generator foundation outside the ‘A’ row.. 7.. Lift stator and place it on the foundation.. 8.. Align the stator w.r.t centreline and the LP rotor.. 9.. Place bottom end shield LPT side.. 10.. Insert rotor.. 11.. Place bottom end shield exciter end and align.. 12.. Install and align blower.. 13.. Attach seal ring carrier and align.. © PMI, NTPC. 36.

(39) 14.. Position top end shields and tighten.. 15.. Install hydrogen coolers.. 16.. Align generator rotor w.r.t. LP rotor and tighten anchor bolts.. 17.. Install seals.. 18.. Couple generator rotor with LP rotor.. 19.. Check exciter foundation and place sole plates.. 20.. Place exciter on sole plates, level and align.. 21.. Align exciter rotor with generator rotor and tighten anchor plates.. 22.. Couple exciter rotor with generator rotor.. 23.. Prepare for oil flushing.. 24.. After completion of oil flushing control fluid flushing, seal oil flushing and stator water flushing the unit is ready for putting on barring.. Note: PROTOCOLS ARE TO BE MADE AS PER THE FIELD QUALITY PLAN G.. Ensure all other inputs are established as follows; a.. Boiler. b.. Piping (including hydrotest and steam blowing). c.. Auxiliaries. d.. Instrumentation. e.. Other packages. The unit can then be rolled and prepared for synchronization.. © PMI, NTPC. 37.

(40) © PMI, NTPC. 38.

(41) 3 X 500 MW TG PACKAGE NTPC INPUTS (REF PERT NETWORK SH. 1 OF 2) S. No.. Input. Description. 1. D. 1. Condenser Foundation 2. EOT crane. 3. Area for labour/staff quarters. 4. Project railway siding and Rail track up to TG hall. 5. Approach road to TG hall.. 6. Power & water supply. 7. Storage / office area 8. TG hall with approach side walls roof. & lighting 2. E. 1. TG foundation. 2. TG 17 ‘m’ floor 3. TG 8.5 m floor 4. TG ‘0’ m floor 3. F. 1. LT Power. 2. Cable for Oil pumps. 3. Instrumentation. 4. G. © PMI, NTPC. 1. Complete Instrumentation. 39.

(42) S. No.. Input. Description. 5. H. 1. Readyness of main boiler. 2. Completion of Regenerative system equipment e.g. Deacrator, LP heaters, HP heaters piping, BFPs, condensate Ext. pumps.. 3. Unit aux. Transformer 4. Complete UCB with instrumentation.. 5. Generator Transformer 6. Switch yard & control room. 7. Power evacuation system/grid. 6. I. 1. Stator unloading track.. 2. Portal crane foundation. 7. J. 1. All auxilliaries foundation. 2. Pipe supporting stracture 3. Auxilliary platform & approach stair cases. 4. DM water.. 5. Instrument / Plant air.. © PMI, NTPC. 40.

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(44) © PMI, NTPC. 42.

(45) 8. Boiler Feed Pumps 3 X 500 MW MW STEPS INVOLVED IN ERECTION The erection activities are broadly classified into the following categories:. A.. B.. C.. Main equipment. Auxiliaries. Piping. © PMI, NTPC. i). Main Pump. ii). Booster pump. iii). Drive Motor (for MDBFP). iv). Voith coupling (for MDBFP). v). Drive Turbine (for TDBFP). vi). Gear Box (for TDBFP). i). Lub oil coolers. ii). Working oil coolers (for MDBFP). iii). Lub oil tank (for TDBFP). iv). MOPs/AOPs and EOP (for TDBFP). v). Gland drain tank. vi). Emergency seal water pump. i). Feed water suction/discharge. ii). Lub oil/control oil. 43.

(46) D.. E.. F.. Instrumentation. Interface. Customer Inputs. © PMI, NTPC. iii). Steam lines - HP/LP, gland steam. iv). Seal water. v). Cooling water. i). Control panels. ii). UCB consoles. iii). Field panels, instruments, junction boxes. iv). Cabling. i). Civil foundation take over. ii). Equipment terminal points take over/hand over. iii). Cable termination checks. i). Safe working area. ii). Foundations. iii). floor - ‘O’ M, 8.5 M & 17 M. iv). Lighting. v). Approaches to TG hall and fans. vi). EOT crane. vii). Construction power. viii). Equipment power supply. 44.

(47) TURBO – DRIVEN BOILER FEED PUMP A.. Main Equipment. The TDBFPs are located at 17M operating floor of TG Hall. There are two TDBFPs of 50% capacity. Unlike MDBFP the TDBFPS are delivered to site as separate units comprising of main pump, turbine, and Gear box + Booster Pump in a common frame. They are located on top of the concrete condition deck.. (The concrete foundation deck is freely supported on springs which are placed on steel structure raised from pipe foundation. This is done to achieve high degree of vibration isolation. which. prevents. transmission. of. vibration. from. BFPs. to. the. adjacent. structure/equipment and vice versa). 1.. The erection procedure is given broadly in the enclosed sheets FE to FE4.. © PMI, NTPC. 45.

(48) 9. Field Erection Procedure 1.. Install all parts below the turbine floor which can be easily installed now, before the turbine is put in place.. 2.. Install the oil unit.. 3.. Check foundation dimensions and location of the foundation bolts before starting erection. Check Position of pipe connections against customer elevation plan. Mount the sole plates to the turbine supports.. 4.. Refer to drawing, fit the jack bolts and the foundation bolts in the holes, which have been provided in the sole places of the turbine.. 5.. Place steel plates, approx. 100 x 100 x 10 mm on the foundation, so that these plates will take the thrust of the levelling screws.. 6.. Lower the turbine on to the foundation and level it transversely and longitudinally using the jacking bolts. Adjust the distance between the top of the concrete foundation and the bottom of the sole plates to 20-25 mm. Forms or dams around the sole plates are required.. 7.. Mount all steam and oil piping to the turbine.. 8.. Mount the sole plates to the boiler feed pump supports. Fit jack bolts and foundation bolts in the holes which have been provided in the sole plates.. 9.. Place steel plates, approx. 100 x 100 x 10mm on the foundation, so that these plates will take the thrust of the levelling screws.. 10.. Lower the boiler feed pump on to the foundation and level it transversely and longitudinally using the jacking bolts to align the pump shaft with respect to the turbine shaft. For alignment data see the alignment protocol in the last section of this book. Forms or dams around the sole plates are necessary.. © PMI, NTPC. 46.

(49) 11.. Fit the jacking bolts and foundation bolts in the bottom flange of the booster pump bedplate. Tighten the bolts of the levelling pads.. 12.. Place steel plates, approx. 100 x 100 x. 10mm on the foundation, so that these plates will take the thrust of the levelling screws.. 13.. Lower the baseplate, with the booster pump and gear box in place but the coupling disconnected, on to the foundation. Using the jack bolts, level it transversely and longitudinally to align the couplings between the booster pump and gear box and between the gear box and turbine. For alignment data see the alignment protocol in the last section.. 14.. Mount all water and oil piping to the booster pump and gear box, and check the coupling alignment.. 15.. Fill the holes of the booster pump foundation with grout, in such a way that the half of the shim thickness is in it. See detail “A” below. Use a non-shrinkable flowable grout. Make provisions that the levelling screws stay free of the grout.. © PMI, NTPC. 47.

(50) 16.. Allow the Grout to dry (according to the manufacturer’s prescription).. 17.. Loosen the leveling screws and tighten the foundation bolts and keep checking the alignment. Tightening of the foundation bolts should have no effect on the alignment of the set. If it is necessary to make a correction in the leveling of the booster pump bedplate, handle as follows: Loosen the foundation bolts, loosen the tap bolts of the shims, level the bedplate by means of the leveling screws, fit between the shims and the supporting pads the required liners, loosen the leveling screws, tighten the tap bolts, tighten the foundation bolts and check the alignment again.. 18.. Grout the turbine and the boiler feed pump to the foundation in such a way the half of the sole plate thickness is in the grout. Use a non-shrinkable flowable grout. Make provisions that the leveling screws stay free of the grout.. 19.. Allow the grout to dry (according to the manufacturers prescription).. 20.. Loosen the leveling screws and tighten the foundation bolts and keep checking the alignment. Tightening of the foundation bolts should have no effect on the alignment of the set. Make any required correction.. 21.. If it is necessary to correct the radial coupling alignment, this, should be done by changing the thickness of the shims under the supports of the respective components.. 22.. Remove the boiler feed pump inner assembly in accordance with the instructions given in the maintenance section.. 23.. Weld the pipes to the respective pump nozzles in such a way that no forces and / or moments are exerted on the nozzles.. 24.. Connect the other water and oil pipes to the boiler feed pump. Also without exerting forces and / or moments by the piping.. © PMI, NTPC. 48.

(51) 25.. Remove the booster pump inner assembly in accordance with the instructions in the stork instruction manual.. 26.. Remove the inlet filter inner assembly in accordance with the manufacturer’s instruction.. 27.. Prepare the set for pickling by blanking off the relevant openings.. 28.. It is strongly recommended by Delaval Stork that the pickling is done by a company which is a specialist in this field. Such a company will have the necessary equipment available and possesses the technical knowledge. Pipes that have been furnished by Delaval-Stork with the unit, have been pickled before leaving the shop.. 29.. After pickling, remove all blanking plates and reinstall the boiler feed pump inner assembly, the booster pump inner assembly and the inlet filter assembly.. 30.. Check the alignment .of the couplings. Make any required corrections.. 31.. Flush the oil system in accordance with the flushing instructions given in the operation section.. 32.. Prior to the initial start, make an overall inspection to make sure that all accessories have been properly installed.. 33.. Make sure that the coupling between the boiler feed pump and turbine is disengaged. Make sure that the coupling between turbine and gear box is connected so that the mechanical over speed trip can be tested during the test run.. 34.. Before starting the turbine remove the transport rings items.. 35.. Blow down the steam inlet line before allowing steam to enter the turbine. Make sure that the steam pipes are reasonably clean and do not contain sand, welding beads or other harmful material.. 36.. The turbine should be isolated in accordance with drawing and Technical Specification.. © PMI, NTPC. 49.

(52) 37.. Check and, if necessary, adjust all the relevant control and safety device settings and start the turbine for a test run.. 38.. After the turbine test run, stop the turbine and engage the coupling between the turbine and boiler feed pump. Make up the coupling between the gear box and booster pump.. 39.. Start the complete unit in accordance with the instructions given in the operating section.. 40.. If there are objections against the coumping alignment at operating conditions, a hot alignment check can be made as follows: couple up the unit and run it with indicators mounted on a bridge tupe bracket as shown on the attached sketch to check the alignment under operation condition. Indicators should be zeroed when the machined is cold and read and recorded after normal conditions have stabilized. Before shut down, the indicators should be reset at zero and readings should be recorded after the unit has cooled. Make any required correction. Record coupling alignment on drawing for adjusting data.. © PMI, NTPC. 50.

(53) © PMI, NTPC. 51.

(54) © PMI, NTPC. 52.

(55) B.. Auxiliaries. Auxiliaries for MDBFP are lub and working oil coolers. Gland drain tank and DC emergency seal water pump. Lub and working oil coolers are located at ‘O’ M level on the floor. Gland drain tank is located at minus 2.5 M level.. 1.. Check foundation pockets for the cooler with respect to drawing.. 2.. Place the coolers on the foundation correctly w.r.t. x, y & z planes.. 3.. Grout the cooler with ordinary grout mix.. MAKE PROTOCOL FOR TERMINAL POINTS 4.. After curing for 3 days piping work on the equipment can be taken up.. 5.. Gland drain tank is placed at ‘O’ M level on insert plates on the floor at the designated location after ensuring its level and then tack-welded.. MAKE PROTOCOL FOR TERMINAL POINTS 6.. Steps 1 to 4 are identical for DC emergency seal water pump.. MAKE PROTOCOL FOR TERMINAL POINTS. C.. PIPING. a.. Feed water piping. 1). All the piping has to be erected in position in totality before it is connected to the booster pump or the main pump this means. © PMI, NTPC. 53.

(56) i). All welding joints/flanged joints other than the one with the pump are complete in all respects i.e. radiographed, stress-relieved, permanent gaskets installed, all flanged bolts tightened.. ii). All hangers are installed.. iii). All spring hangers are delocked and adjusted to their cold values.. iv). All restraints are installed.. v). Insulation and cladding has been completed.. vi). There are no temporary supports or lifting or pulleying tackles attached to the pipeline.. vii). In the above condition the joint with the pump is fully in alignment within the welding tolerance/flanged joint tolerance. Usually the ID of the pipe should be within ± 1mm of each other. The line should be free to swing if forced and then return to the original position. This is called a FREE JOINT.. MAKE PROTOCOL OF THESE CONDITION i) to vii). 2.. Mount dial gauges to the coupling hubs of the equipment involved in the final weld joints to monitor if any undue forces are transmitted to the equipment during welding which might disturb the equipment during welding which might disturb the equipment alignment. Same applies for flanged joint.. 3.. Allow final joint to be welded / bolted.. 4.. If any appreciable deflection is observed on the dial indicators then change the welding sequence 1800 out of pahse in order to compensate the distortion.. 5.. The above procedure is valid for all the feed water piping connected to the pumps.. © PMI, NTPC. 54.

(57) Note: 1.. Ensure that all piping are clean on the inside and free of rust, sealed and debris. For this purpose pipes are acid pickled and then neutralised. Alkali flushing of the pipes may be carried out for suction lines before the suction strainer and feed lines going out of the pump. Oil should Not be applied to the internals of the non oil lines to prevent rusting.. 2.. Hydro test of lines is ensured at an appropriate tage.. b.. Cooling water, seal water lines:. 1.. Lines are connected from one terminal point to the other as per the drawing.. 2.. Seal water lines are acid pickled to ensure that water supplied to the pump seals is free from scales and dirt.. 3.. Flushing of the seal water lines and cooling water lines is done to ensure removal of all debris and free matter.. c.. Oil lines. 1.. Lines are pre-fabricated and erected in the normal manner. 2.. If not already acid pickled then suitable sections are then made to remove the complete piping for acid pickling and cleaning.. 3.. Lines are reassembled.. 4.. Pressure test of the lines is carried out according to the drawing requirements (15 times the design pressure).. 5.. Oil Flushing:. The purpose of oil flushing is to achieve completely clean internal surface of oil pipelines before oil can be supplied in such lines to bearings, gears, control valves etc.. © PMI, NTPC. 55.

(58) i). Remove the bearing half from main pump, booster pump and motor and replace them with auxiliary bearings.. ii). Install bypass lines in the control oil circuits for all servo devices.. iii). Fill Voith coupling oil tank with oil up to the specified level.. iv). Ensure that the filter element on the Voith coupling inlet are in position and in clean condition.. v). Keep the oil incirculation by auxiliary oil pump of the Voith coupling.. vi). Thermal shocks are given to the pipelines by heating the oil to 75°C holding it for 30 mms and then suddenly cooling to 35°C. This is repeated several times to loosen all scales etc. And until no more dirt comes into the filters.. Heating of oil can be achieved by admitting hot water into the oil cooler by suitable arrangement which can be interrupted to supply cold water. vii). All lub oil lines are then normalized according to the drawing taking care that no foreign material enters the lines.. ix). Flushing oil is then drained and fresh oil is charged into the system.. x). Oil system is now ready for pre-commissioning and commissioning.. Motor Driven BFP A.. Main Equipment:. 1.. Ensure approach to the main BFP foundation at 8.5 M floor. 2.. Ensure SAFE working conditions. 3.. a.. Check completeness of foundation and measurements as per the civil and mechanical drawings.. © PMI, NTPC. 56.

(59) b.. Check levels of foundation w.r.t. drawings and plant bench mark. c.. Ensure cleanliness of foundation. MAKE PROTOCOL OF a) AN]) b) WITH DIMENSIONS FOR TAKING OVER THE FOUNDATION 4.. Dress/chip foundation pedestal tops to make it even and free of debris/loose cement. Also ensure foundation pockets/bolt holes are free of loose cement and concrete.. Foundation is now ready for placing the equipment.. The Motor driven BFP is delivered to site on a common steel skid the main pump, booster. pump. and. Voith. coupling. are. already. mounted. on. the. skid.. The drive motor for BFP is delivered separately to site.. 5.. Place steel plates 100 x 100 x 10mm thick on the foundation at location where levelling bolts /jacks bolts on the skid are located so that the complete skid can be placed on its jack bolts on top of these plates.. 6.. With the help of lifting beam and the slings (as per the relevant drawing) left the total skid and place it on the foundation.. 7.. Lower the Drive motor on the skid and secure it with the bolts provided.. 8.. Level the skid w.r.t plant bench mark within ± 1 mm.. 9.. Adjust the levelling screws so as to achieve parallelism of all the coupling faces with ± 0.02 mm.. 10.. Remove rotor locking device (transport device) from all equipment and check complete alignment of the respective equipments in accordance with drawing. Adjust, if necessary, by using SS shims under the feet of the equipment to within the tolerance limits given in the drawings. It is customary to take ‘Voith Coupling’ as the reference point and align the other equipment w.r.t it. The skid is now ready for grouting.. © PMI, NTPC. 57.

(60) MAKE PROTOCOL FOR ALIGNMENT BEFORE GROUTING 11.. Keep the foundation pockets (42 Nos.) and its surroundings wet by water atleast 3 hours before grouting. Place foundation bolts in position.. 12.. Make wooden frame work around the bolts and grout with non shrink grout mix.. 13.. After 3 days of curing remove the framework. Loosen all the jackbolts and tighten all foundation bolts.. 14.. Check alignment of all equipment at the couplings. Adjust/correct if required.. MAKE PROTOCOL FORALIGNMENT AFTER GROUTING & BEFORE PIPING 15.. Hand over the terminal point for Feed Water piping after checking its location.. MAKE PROTOCOL FOR HANDLING OVER OF PIPING TERMINAL POINTS 16.. Equipment is now also released for instrumentation and electrical jobs.. 17.. After completion of all piping work check the alignment of all the equipment again Make corrections, if necessary.. MAKE PROTOCOL OF ALIGNMENT AFTER ALL PIPING 18.. All the equipment are then dowelled as per the drawing.. 19.. Place coupling spacer between main pump, voith coupling, Motor and Gear box and tighten to the specified torque.. 20.. Equipment is now ready for other pre-commissioning and commissioning activities.. © PMI, NTPC. 58.

(61) © PMI, NTPC. 59.

(62) © PMI, NTPC. 60.

(63) 10. 500 MW Generator Erection The various stages involved in the erection of a 500 MW Generator Stator are its transportation from the manufacturers works to site, unloading and placement on foundation.. TRANSPORTATION The dimensions of the Generator Stator are: Length. 8830 mm. Width. 4100 mm. Height. 4020 mm. Weight. 265 MT. The stator is transported on a special wagon consisting of 24 axles i.e. 8 bogies (4 on each side of stator) of 3 axles each with facility to swiral. These two sets of bogies are connected by a carrier beam and the beam is pivoted to the bogies.. The procedure of handling of generator stator on receipt of same at site comprises of the following two major activities.. 1.. Unloading of Generator Stator from the special wagon in the unloading bay outside the TG hall.. 2.. Erection of the portal crane and shifting of Generator stator from unloading bay into its foundation using portal crane.. UNLOADING Before the unloading is done, the following inputs are to be ensured.. 1.. Availability of EOT crane in TG hall.. © PMI, NTPC. 61.

(64) 2.. Completion of civil foundation for unloading of stator, placement of fabricated pedestal and placement of jacks.. 3.. Rail track should be ready for stator shifting.. 4.. There should be an easy access to mobile crane of 75 T capacity around the unloading bay. After ensuring the above inputs, the unloading of generator stator is carried out in the following manner.. 1.. Position the special wagon so that the transverse centre line of the stator coincides with. the. extended. transverse. axis. of. Tg. stator. on. the. rail. track. (See fig. 1) 2.. Insert packing plates between the stator and pedestal behaving a gap of 2-3 mm.. 3.. Adjust the position of the hydraulic jacks (4 Nos. each of 175 MT capacity).. 4.. Dismantle the support beam on both front and rear end of the stator.. 5.. Pressurise all the jacks simultaneously and insert the packer plates and transfer the load of stator from the carrier beam wagon on to the pedestral by lowering the jacks.. © PMI, NTPC. 62.

(65) 6.. De-couple the vacuum pipe assembly of the rear end as well as front end of the wagon bring the roller block on the carrier shield on rear side in engaged position so that the beam can be raised up while lifting the stator by jacks.. 7.. Slowly raise the stator slaotingly by pressurising rear side jacks so that the carrier beam is off the rear side bogie assembly and sufficient gap between the carrier beam and bogies is available to facilitate movement of the rear set of bogies independently. Insert the packers and lower the jacks.. 8.. Move the rear set of bogies towards the rear end approx. to a distance of 25 metres. By doing so the carrier beam gets released off the rear set of bogies and is left supported on the roller blocks on the carrier shield at the rear end.. 9.. Move the front set of bogies alongwith the carrier beam slowly till the rear end of the carrier beam has just reached upto the rear carrier shield of the stator.. 10.. Adjust the stator by means of the jacks so that the carrier beam is being supported now by the guide roller device of the front. Carrier shield cover and the roller device at the rear end carrier shield cover is getting free. Remove the carrier beam carefully out of the stator until a position is reached, when the jacking trolley can be put underneath the beam.. 11.. Place the jacking trolley on the front side between stator and bogies and support the carrier beam closes to the stator. When changing load this way, the guide roller device at the front shield cover must become free of load.. 12.. Move the front set of bogies further till the carrier beam is moved out of the front and carrier shield of the stator.. 13.. Dismantle and remove the front as well as rear end carrier shields.. 14.. Place and assemble the temporary end covers on both end of the generator stator.. © PMI, NTPC. 63.

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