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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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&.'.+. 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. &.'.,. -nsure ...+ feeler tightness on bearing parting plane. $n case of any variation the matter may be referred to designers. &.'./. 0easure bore dia of the bearing and journal dia at site and ensure the oil clearances. $f any discrepancy is observed designer may be referred. &.'.1. -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 site23 $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 4enter 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 ...+ 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 ...+ 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 ...+ mm. the bearing are not accepted at site and can be sent bac! for the rectification to the wor!s. 5imilarly 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. 6efore sending bac! the bearing to the wor!s the matter may be referred to designers and their concurrence is to be obtained. *o 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. 6ut 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 ...+ mm then the matching(lapping may be carried out at site. 6ut in case of higher gap the matter may be referred to designers. $n case of reverse case if the feeler gap of ...+ is noticed on both sides of the bearing the bearing may not accepted at site and matter may be referred to designers.

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&.'.7. 6efore chec!ing the contact between torus and its seat ensure that the seat is feeler tight to ...+ mm without tightening of any bolts with the pedestal. $f necessary this may be corrected with consultation of designers. 5imilarly ensure contact between torus8 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. &.'.9. 6efore 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. &.'.:. 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 +3, 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. &.'.&&. 4hec! 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 $<4. &.'.&+. After installation of bearing in position the oil clearances may be chec!ed after few rotation of the shaft. 6ut 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. 6earing bore dia is to be measured by assembling and tightening of top = bottom halves of bearing. &.'.&,. $n case of s!ew side oil clearances the investigation may be carried out if necessary consult manufacturing unit. &.'.&/. -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. &.'.&1. 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. &.'.&7. 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.

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&.'.&9. 6efore 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. &.'.&:. After fitting of the bearing cap if the gap for the radial top !eys are taper a proper correction is to be made here. The bearing cap may also repositioned to achieve the parallelity of the !ey way. The cap may be doweled after repositioning it but no taper are to be left on these area. repositioning of cap is not helping then the cutting may be carried out bearing cap. in be re3 $f in

&.'.'.. 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. 5ometime the si;e of this pac!er comes to very low i.e. even below /... mm. This may be corrected by matching the cap and si;e for this pac!er may be !ept around 1... 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', 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 ? ..+mm in shim si;e from manufactured condition. &.'.'+. 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. &.'.',. 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. &.'.'/. Adjustment of shims between spherical(torus and bearing body is limited to ?..+. 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. @or 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. *ow some specific points are detailed here for the assembly of combined Thrust and %ournal bearing2

)emove all the thrust pads before placement of bearing in position and store them in a proper place.

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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 a"ially. by moving spherical seat of the bearing radially and

*o elongation of holes are to be carried out in spherical sat of the bearing for the purpose of its alignment. 6efore 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.

0ovement in the thrust pad should be ensured and a difference in thic!ness of pac!ers including shims should be with in ? ..&. 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 to the bearing during fitting of these a"ial !eys. *ecessary 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 ..&.(..&/ mm.

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6efore 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 Asi;e between thrust collar and bearing bodyB.

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 ? 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 ..+. ? ..&.mm during color matching of the thrust pads. $f necessary the minor adjustment of shims may be carried out in the bearing pads.

6efore 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 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 type of bearing if the bearing contact are to be

rechec!ed and need correction. $n case of torus to cylindrical the contact are not satisfactory then the $n spherical can bearing and its seat may be remachined at wor!s. be corrected

to spherical bearing the variation in contact if noticed

by matching(lapping at site. 5ometimes the Page *o. 1 of +'

heavy pitting mar!s are also noticed on same of the bearing and these need correction by machining it.

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BUMP TEST
The axial clearance chec i! "e#er$ine" a%#er ra"ial clearance $ea!&re$en# ha! 'een c($)le#e". In #hi! ca!e #he !ha%# i! !hi%#e" in #he *+, an" *-, "irec#i(n! %r($ i#! ()era#in. )(!i#i(n an" #he "i$en!i(n! /i#h #he !ha%# in li$i# )(!i#i(n are $ea!&re" &!in. a "e)#h .a&.e.

N(#e0 En#er #he $ea!&re" 1al&e! 2 ac#&al "i$en!i(n! 3 (n #he rec(r" !hee# an" c($)are #he$ /i#h #he !)eci%ie" "i$en!i(n!.

I% #he "e1ia#i(n! %r($ #he !)eci%ie" "i$en!i(n! i! .rea#er #hen #he )er$i##e" #(lerance!4 #he $an&%ac#&rer $&!# 'e c(n!&l#e".

N(#e 0 Ba!e" (n #he rea"in.! (% '&$) chec 4 axial )(!i#i(n (% #he !ha%# /r# ca!in. i! n(# #( 'e al#ere".

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2.

ROLL C5EC6
2.1. GENERAL DESCRIPTION

$n KWU machine the minimum radial clearances HP $P and CP 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. 5uch 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.

2.2. PROCEDURE
ROLL C5EC6 OF 5P AND IP CASING '.'.&. Alignment and coupling of HP3$P and CP rotors are to be completed before starting the rolling test of the casing in normal case but this can be done without coupling of CP rotor also.

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'.'.'. 4entering 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. @i" 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. '.'.+. All the four jac!ing screw of HP and $P casing are to installed along with dial gauges for monitoring of up and down and left and right movement of the casing. '.'.,. <ne number hydraulic jac! on each corner of the casing along with a spanner on each corner for jac!ing screw are also to be made available. '.'./. #uring erection of machine the turbine rotor are generally rotated by hand with the help of periphery holes on coupling. Two pipes of about &'/. mm long along with a pin to suit the dia of periphery may be used for rotating the rotor shaft. The initial jer! to the rotor is given by the help of crane and it is further rotated by these pipes through periphery holes of the coupling. #uring overhauling generally the jac!ing oil system is available and the rotation of rotors are achieved with the hand barring of the machine. '.'.1. 6efore starting the rolling chec! it should be ensured that the rotor shaft is absolutely free on manual rotation(hand barring as the case may be. #uring manual rotation two persons are to be employed for this wor! and during hand barring only one person is enough. '.'.7. Always use thic! oil for rotation of rotor over bearing in absence of jac!ing oil system. The type oil may be servo cylinder &... grade A$<4B oil. '.'.9. #uring the rolling test the temporary casing pac!ers are to be fitted with about &... mm shims. '.'.:. #uring the rolling test of any one of the casing the same is lifted first on all four corners in a step of .../ 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 .../mm 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 .../ 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. As soon as the shaft becomes tight the lifting of casing and

rotation of shaft is stopped and dial readings on front end are Page *o. &. of +'

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 .../ mm and freeness of rotor is ensured. $n case it is still tight the casing is further lowered by .../ mm. <n front end and the freeness of rotor is achieved. *ow 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 ;ero3;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. 6efore starting the rolling test in downward direction of the casing remove about &... mm shims from each pac!er of the casing but its !ept the casing on hydraulic jac!s and jac!ing screws on its original position. The casing is again brought bac! to 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 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 dial readings of spigot final are recorded on front and rear end.

$mmediately after this the final radial !ey of the casing are fi"ed Page *o. && of +'

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. '.'.&.. 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. '.'.&&. *ecessary offset in the radial clear3ance is also !ept before fitting of final pac!ers of the casing toward the lift of the shaft during operation of the unit. '.'.&'. *o 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.

'.'.&+. )adial clearance of the casing are to be ensured with reference to the factory supplied protocol also. '.'.&,. 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. '.'.&/. The horn drop readings are also to be chec!ed after the fitting of final pac!er of the casing. '.'.&1. $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. '.'.&7. #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. '.'.&9. @our 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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2.7.

ROLLING TEST OF L.P. INNER CASING

'.+.&. The rolling test of C.P. inner casing is done similar to the HP or $P casing but both side joints of C.P. inlet bellows are !ept free or bellow itself are not positioned at all till completion of rolling test. 6ut during overhauling the rolling test is done with already welded bellows. '.+.'. )olling test of C.P. inner casing is done after the nec! welding of condenser andstiffener pipes inside the condenser. This include the welding of stiffener pipes of C.P. casing and gusset plates also. '.+.+. After rolling test of the casing the final radial !eys of the Dusset bloc! and casing pac!ers on all four corners are installed. '.+.,. *ecessary offset in the radial clearances of the casing is also !ept before fitting of final C. P. inner casing pac!ers. '.+./. )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. '.+.1. $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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7.

CATENARY AND ALIGNMENTS


7.1. General De!cri)#i(n

The catenary of the machine is very important for a turbine and Denerator 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 maintain the catenary high bearing vibration high babbitt metal and subse>uent

temperature of the bearing etc. To avoid these problems it is necessary to of the machine during erection realignment(overhaul of the unit. 0any 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 C.P. front and C.P. rear pedestal are directly grouted pedestals are not very convenient here without any separate base plate. As such any correction on lifting or lowering. These so if necessary the rotor may be lifted or even regrouted during lowered with respect to pedestal seal bore and re>uired catenary may be achieved. $n e"treme cases these pedestals may be major overhauls of the unit to correct the catenary of the machine. 7.2. Pr(ce"&re

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+.'.&. $nstall a bench mar! plate near C.P. rear pedestal as height of the machine center line with the consultation of civil -ngrs at site. A plate of '.. m.m " +.. m.m si;e with '. m.m thic!ness machined(ground on top side may be welded over a $ 6eam 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. +.'.'. )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. +.'.+. #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 ?value 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. +.'.,. @or better results four water level jar connected to each other with a polythene pipe may be installed on each pedestal. The #.0. 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 &'/ 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 &7/ 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 .3&.mm dial gauge may be used. +.'./. .#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. +.'.1. While finali;ing the catenary of the machine these measurements are to be repeated +3, times in a day at different intervals to avoid any possibility of the error. +.'.7. The height of the C.P. rear pedestal is the reference point for setting the height of all other pedestal and C.P. base plates. The C.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. +.'.9. The benchmar! plate is to be preserved for all future references.

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+.'.:. 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. +.'.&.. After ensuring the re>uired catenary of alignments are to be made as parallel coupling. the machine the coupling

+.'.&&. 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. +.'.&'. @or measurements of direct journal height a special fi"ture is to be fabricated and necessary information about it can be separately given by P53T5 if such necessity arises.

8.

5ORN DROP TEST


8.1. General "e!cri)#i(n

6y 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. @irst 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.

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 Page *o. &1 of +'

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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8.1.1. Pr(ce"&re ,.&.'. 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. ,.&.+. 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. ,.&.,. 6efore 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. ,.&./. *o 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. ,.&.1. *o 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!. ,.&.7. 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. 6efore 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. ,.&.9. $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. ,.&.:. $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. ,.&.&.. 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. ,.&.&&. 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.

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,.&.&'. #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. *ow 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 ? adjustment of shims from left to right side or vise3versa. *o 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. ,.&.&+. 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. ,.&.&,. #uring the initial horn drop the best reading within .../(...1 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. ,.&.&/. $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. ,.&.&1. 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. $f necessary a fine adjustment may be carried out at this stage to achieve correct value of the horn drop reading. ,.&.&7. After completing the welding of all pipe lines with the casing the horn drop readings are repeated again for comparison with the earlier readings. These readings are ta!en along with its radial and a"ial !eys of the casing. ,.&.&9. #uring this stage e"actly this can not be defined that how much variation is permitted on these values of horn drop readings. 6ut this variation will indicate the influence of the piping load on the HP($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. 6ut 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.

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,.&.&:. #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. ,.&.'.. The variation in horn drop reading of left and right side of a casing may be permitted upto a difference of /.E. ,.&.'&. The horn drop readings are not ta!en for C.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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9.

S:ING C5EC6
9.1. 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 chec! values permitted caused due to the can be #esignerFs on the coupling faces of the rotor resulting to some swing chec! values. The ma"imum swing above tolerance for different diameter and length of the rotor

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 Turbine3Denerator system it is essential to measure the swing chec! value in both e"treme end and where the weight of the rotors are light. @or e"ample '..('&. 0.W. KWU machine with )ussian Denerator and static e"citation system the swing chec! values are measured on HP rotor front end only. $n /.. 0.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 '.. 0W = /.. 0W units a necessity is felt to measure swing chec! value on $P rotor front end also for better results during operation of the units. This can be done initially during erection with temporary coupling bolts on CP3$P chec! during the coupling before reaming(honing of coupling. Any Any compromise at stage. The correction erection may be variation in swing

values may be corrected without any hesitation during erection of machine. stage may cause serious problem carried out either operation of the unit and any correction becomes much more tedious a later by interchanging

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coupling position

or

by correcting

the

coupling

faces

by

scrapping(cutting in consultation of #esigners.

9.2.

PROCEDURE

/.'.&. 6efore placement of 0odule()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. *o conve"ity is permitted on these coupling faces however a concavity of about ...+(..., mm is permitted. $n case of any variation the matter may be referred to manufacturing units. /.'.'. After placement of individual 0odule()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. 5imilarly C.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. /.'.+. 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.

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/.'.,. #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. /.'./. #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. /.'.1. @irst $P3CP coupling is to be made with temporary bolts and swing chec! on $P rotor front end is recorded. After this only HP3$P rotor is to be coupled with temporary bolts and the swing chec! value on HP front rotor is recorded. /.'.7. #uring swing chec! of $P rotor its front end is to be supported on lifting tac!le without ma!ing any connection between HP3$P rotor. /.'.9. While recording swing chec! of HP rotor the front end of the rotor is to be supported on lifting tac!le. /.'.:. #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 0oly!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. /.'.&.. 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. /.'.&&. #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. /.'.&'. After ensuring the swing chec! values as per the graph with on temporary coupling bolts the HP3$P and CP3$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. /.'.&+. The final swing chec! value of HP front rotor is to be recorded after fitting( elongation of all the coupling bolts of HP3$P = CP3$P rotors. Any variation in readings may be referred to the #esignerFs. @or improvement of the swing chec! values the indifferent tightening and non3se>uential /.'.&,. #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. /.'.&/. 5imilar 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. /.'.&1. 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.

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COUPLINGS ; ALIGNMENTS OF ROTORS


9.7. GENERAL DESCRIPTION

The coupling on turbine shaft are generally rigid coupling but in case of C.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 ...+(..., 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. #uring the alignment of two coupling both are to and by be turned in same direction the

the same amount when the measurement are ta!en to avoid

influence of the a"ial = radial runout present in the shaft caused due to the machining. Page *o. ', of +'

9.8.

PROCEDURE

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/.,.&. 6efore placement of module(rotor in position chec! and record the coupling hole and journal dia of the shaft. /.,.'. 4hec! coupling faces for the concavity(conve"ity with the help of a thin rectangular straight edge before placement of module(rotor in position. /.,.+. 4hec! spigot and recess of the placement in position. coupling and ensure their fitting before

/.,.,. 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(CP 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. /.,./. The HP $P = CP rotor are aligned together and then their couplings are made. After fully completion of HP($P = $P(CP coupling with tightening of their final bolts the complete shaft is cleared for Denerator rotor alignment. /.,.1. #uring initial alignment of HP($P = $P(CP 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. /.,.7. #uring final alignment only the a"ial gap values are chec!ed at :.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 CP 3 Den coupling the radial dial reading are also ta!en. /.,.9. Avoid rotation of two shaft in their spigot. $f necessary these may be rotated after ta!ing out from their spigot. /.,.:. #uring alignment of shafts the adjustment of shims in bearing torus may be fully avoided. The margin of ? ..+. mm. in height = left(right direction may be !ept for emergency wor!s only. Any adjustment during erection and normal overhauling may be done by adjusting shims between spherical(cylindrical seat and pedestal base only. @or left and right adjustment the complete H.P. front and HP rear pedestal may be moved with the help of their radial !eys. /.,.&.. The final pac!ers of the pedestal and base plates are fitted before the grouting of the pedestal itself and here no adjustment is necessary during erection of the machine. 6ut during overhauling of the machine the adjustment may be carried out in these pac!ers for correction of catenary of the machine. /.,.&&. #uring alignment of rotor ma!e HP($P and $P(CP coupling gap parallel. After completion of final alignment no adjustment of pac!ers and !eys etc are permitted on pedestals and bearing the final alignment of HP($P = $P(CP rotors should be chec!ed after fitting of all the final !eys and pac!ers of the pedestals.

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/.,.&'. After alignment couple the HP3$P = $P3CP rotors on temporary bolts. )ecord coupled runout of the rotor and ensure that the coupled runout is not more then ...+ mm. in any where in the journal as well as in coupling area. 6efore coupling of rotor on temporary bolts record their spigot clearances by actually moving the rotor radially. /.,.&+. #uring erection $P3CP swing chec! on $P front and HP3$P swing chec! on HP front are to be recorded on temporary bolts. These reading are to be ensured within the design limit. /.,.&,. 6efore 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. /.,.&/. The HP3$P = $P3$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. /.,.&1. #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. /.,.&7. 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 ...'(...+ undersi;e. *o banana shape is permitted in any of the hole. The hole should be made to ..../ mm accuracy. /.,.&9. All the coupling bolts are to be machined and ground by ...'(...+ 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. /.,.&:. 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. /.,.'.. All the coupling bolts are to be balanced before finally fitting(tightening in position. These are to be balanced within an accuracy of / 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 &9.o opposite bolts may be made of e>ual weight. /.,.'&. #uring tightening of coupling at any stage first tighten four bolts on :.o location. Always tighten bolts in proper se>uence with &9.o opposite bolts. These bolts are to be elongated to the value given over drgs.

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/.,.''. #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 ...+ mm. on coupling and journal of the shaft. /.,.'+. After final tightening of CP3$P and HP3$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. /.,.',. After completing the coupling wor! alignment may be done. the casing radial and a"ial

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:el"in. (% !#ea$ inle# an" exha&!# )i)e line! /i#h 5P an" IP ca!in.
$n '&. 0W machine the HP Turbine is supplied with two inlet and two e"haust flanges for connection of the pipe line.but in case of /..('/. 0W HP Turbine the casing is supplied with four inlet flanges also. As such in '.. 0W machines only two -5G control valves are used in the system. Whereas in /..('/. 0W machines $t may be either two -5G oontrol valves or four -5G control valves to cope with the design of the casing. 5imilarly in '&. 0W 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 C.P. casing. The /.. 0W $.P. casing is similar to the '&. 0W $.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 '&. 0W machines only two $.G. control valves are used but in case of /.. 0W 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. 5imilarly 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 Piping -ngineers. The piping connection between $.P. casing to C.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 Page *o. ': 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 05 inlet 4)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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<.

PROCEDURE
1.&. The following points are to be ta!en care while welding 05 4)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 -5G = $G valves are to be cleared after fitting of their servomotors and then levelling including the correct elevation etc. 1.&.+. 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. 6efore starting of any welding with the control valve the valves are to be loc!ed for their movement. 1.&.,. -rection and welding of 05 line upto 05 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 05 = H)H lines upto the -5G = $G control valves. 1.&./. $nstall 05 = 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.&.1. Weld 05 = H)H lines with the strainers and again ensure the freeness ( paralalllity of 05 = H)H lines with the -5G and $G control valves. Any minor variation may be readjusted on hangers to obtain the freeness of the joints with the control valve. 1.&.7. $nstall the 05 and H)H lines between control valves and HP ($P casing . *ow 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. 1.&.9. After ensuring the freeness and parallelity of the end joints between -5G control valve and HP casing the same may be welded together. 6ut the stress relieving of all the in 3between joints of the lines are to be completed before ta!ing up wor! of the above last two end joints . 5imilar proceedure may be followed for the lines between $ G valves and $P casing also.

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1.&.:. Weld left and right 05 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 4)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 05 lines but before weling of these line the in3 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 -5G and $ G control valves during erection (welding of these 05 = 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 23 After complete leveling of -5G 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 05 =H)H lines with the strainers . After connection of 05 = H)H lines with the HP = $P casing . After complete insulation of control valve and pipings.

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1.'.+. -nsure proper clraning of 05 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.'.,. The steam blowing of the 05 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.'./. 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.'.1. 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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