Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
FOR
5X55 MW
HYDRO TURBINE
FOR
ALMATTI HYDRO POWER STATION
KARNATAKA POWER CORPORATION LIMITED
CONTENTS
S.NO -
DESCRIPTION
PAGE NO.
1.
3 - 11
2.
12 - 24
3.
TECHNICAL DATA
4.
25- 28
5.
29 -36
6.
TURBINE ASSEMBLY
37 - 63
7.
AUXILLARIES
64 - 67
8.
ANNEXURE -(LOGSHEET) `
68
2.
1.2
1.2.1
i)
ii)
1.2.2
1.2.3
(i)
(ii)
(iii)
1.2.4
Suitable lifting gear should be selected. The lifting tackles which are
properly certified by appropriate authority about load carrying capacity
should only be used. All tackles should be properly maintained. If the
sling marks are not provided on any of the packing for lifting, the sling
1.2.6
1.2.7
On receipt of the equipment check them with the shipping list. Any
omission and damages should be reported back
to BHEL
1.3
STORAGE
The equipment should be accommodated in permanent place of
storage within a week after arrival at destination.
1.3.1
1.3.2
The cases should be arranged in neat stacks away from walls and at
least 100 mm above floor level preferably on rail sections, and also so
far as possible in the sequence of requirement of the parts for erection.
Adequate gangways are to be left for inspection and cleaning. It is also
recommended to repaint weight, upright position indication etc. on the
side exposed for inspection.
1.3.3
To prevent distortion the heavy part and other large assemblies should
be kept on even platform. The articles weighing 10,000 kg and above
should be arranged in a single tier. Parts weighting up to 5,000 kg may
be piled up to a height of 2.5 meters. Small and medium sizecomponents are recommend recommended to be stored on shelves.
1.4
GUIDE PADS
1.4.1
Guide pads supplied by BHEL have thin lining (2 to 3 mm) of tin base
babbit metal chemically bonded to a steel backing. The pads are
polished to high surface finish.
1.4.2
The babbit metal is quite soft and can be easily scored by ferrous
material. These pads should be stored in such a way as to prevent
abrasion, scoring etc. These pads must not be stacked one over
another.
1 .5
FABRICATED COMPONENTS
1.5.1
All these items are generally fabricated from mild steel shot blasted
and painted. The machined surfaces however are treated with
corrosion protective chemicals. As these chemicals are to be removed
before assembly, they are necessarily of temporary nature and can be
easily removed. Sometimes, in addition to this, aluminum foils or
1.5.3
1.6
PIPE WORK
Before the pipes and pipe works are sent to site, the pipes are pickled
and coated with rust preventive coatings. Small bore pipes are plugged
and large bore pipes are covered with flanges.
Drg. No. 32630301005 manufacturing specification for water piping.
Drg. No. 32603031006 manufacturing specification for oil piping.
1.7
INSTRUMENTS
Packing cases containing instruments, relays, motors, etc., are marked
'fragile'. Jerks and impacts should be avoided in handling these. These
cases should be fully opened and inspected for any damage on arrival.
The repair and replacement of instruments takes a long time. It is
recommended that all the instruments are checked for calibration. The
instruments should be repacked giving adequate cushioning. The
instruments could also be stored individually without the packing cases,
but on properly cushioned bases and with adequate protection against
falling objects, accidental impacts etc. All instruments should be stored
in a vibration free area.
For the convenience of site staff a list of major parts and assemblies of
hydro turbine with the recommended storage conditions for them is
given is Appendix "A".
1.8
APPENDIX 'A'
RECOMMENDED STORAGE CONDITIONS
Storage Condition
Description of Assembly
flexible
housing
etc.
for
Guide
bearing
housing,
Valves,
Battle
tray
APPENDIX 'B'
2.0
INTRODUCTION:
2.1
Materials
2.1.1. For site use BHEL recommends the following Temporary Rust
Preventives (TRP).
a) Non-drying Type (Pigmented) BP 55191
b) Drying Type (Pigmented) AA 55155
c) Drying Type (Black) AA 55154
2.1.2 Non -Drying Type (Pigmented) BP 55191
This can be applied with brush resulting in soft non-drying film. This
provides protection for a period not exceeding 4 to 6 months. This can
be removed with white spirit. Because on non-drying nature of the film,
it runs the risk of getting wiped off accidentally and exposing that area
to corrosion. Hence more care is required during storage.
2.1.3 Drying Type (Pigmented) AA 55155
This can be applied with brush resulting in thin dry film, which can be
removed with white spirit Xylol or Toluol. It would provide protection for
a period not exceeding six months.
2.1.4
2.2
b) Toluol
c) Mineral Turpentine (White Spirit)
d) Derusting Solution (Rust Removal) BP 55193
3. 0
SURFACE CLEANING
Before any TRP is applied on any metal surface the surface should be
free from old TRP, rust, grease, moisture etc. It may be emphasized
that the effectiveness of the TRP is reduced or even nullified if the
surface is left contaminated.
3.1
3.2
3.3
3.4
Wipe off the surface with clean cloth having small quantity of
uncontaminated white spirit. Allow the solvent to evaporate. The
surface is now ready for TRP application.
4.0
TRP APPLICATION
The application has been classified into four categories viz., A, B, C&D
keeping in view the status of finish and extent of protection desired.
4.1
Category A
Journal faces, highly finished surfaces (better than 0.8 microns) such
as thrust face, bearing surfaces of Shafts.
4.2
Category 'B'
Large fabricated items having machined surfaces such as Guide
Bearing Support Ring, Vapour Seal Assy, Oil Retaining Sleeve, mating
surfaces, shaft flanges.
4.3
Category 'C'
All fasteners and threaded portions excepting in such cases where the
job has already a protective film each as plating, galvanizing etc.
4.4
Category 'D'
Small machined components & other components not defined above.
5.0
5.1
Jobs classified in Category 'A' and B' will have 3-coat system as
detailed below.
5.1.1
After cleaning, apply one coat of TRP AA 55155 and allow it to air dry
for 12 hours inside the store.
5.1.2
Clean dust from the surface and apply a coat of TRP AA 55154 and
allow it to air dry for about 12 hours.
5.1.3
5.2
5.2.1 After cleaning apply one coat of AA 55154 on non-threaded portion and
a liberal coat of BP 55191 on threaded portion. Allow if to air dry for 12
hours.
5.2.2
5.2.3
5.3
5.3.1
After cleaning apply one coat of AA 55155 and allow it to air dry for 12
hours.
5.3.2
6.0
PRECAUTIONS
6.1
6.2
Container and brush must be cleaned after application with white spirit
before keeping for next operation.
6.3
During the drying period, the wet film should be protected from,
deposition of dust particles by providing an umbrella of polythene
sheet.
6.4
Protections, given for TRP film, such as Aluminum sheet, plywood etc.
should be replaced after application of the TRP. The surface coming in
contact with the job should be given a liberal coat of AA 55154.
6.5
Normally after an interval of six months, the surface of TRP coated jobs
shall be examined for any damage, corrosion spots etc. the repair
should be done and TRP System applied.
6.6
3.3 Final log sheets shall be prepared at each stage of erection work and
signed by representatives of BHEL and customer.
3.4 Even though erection tolerances are given, efforts shall be made to
achieve best possible results.
4. UNPACKING AND CHECKING OF PLANT EQUIPMENT
4.1 All materials shall be unpacked and checked well in advance of
erection work. In case of any damage / shortage, suitable action in line
with QAM/SP shall be initiated to inform concerned agencies. Storage
and preservation of materials shall be ensured as per manufacturer
instructions.
4.2 All rubber products eg. Cup seals, O-rings etc. are preserved till their
use, in chalk powder / water container with water replacement every
week / water soaked saw dust.
5. WELDING
5.1 Welding is carried out by a qualified welder.
5.2 Recommended electrodes are used wherever specified.
5.3 Edge preparation is checked / prepared wherever required as per
drawing.
5.4 Surfaces are cleaned thoroughly before starting welding, surfaces
must be free from foreign materials such as grease, oil, paints etc. for
a distance of at least 20 mm from weld joint on either side.
5.5 Electrodes are suitably baked in oven prior to their use to 300 C at
least for two hours / as per manufacturers guidelines.
5.6 Proper root gap is maintained for welding to avoid undercut, over laps,
abrupt ridges and valleys.
If the gap is more than 5 mm packing strips are provided to minimize
shrinking and welding deformation. These shall be removed before
starting seal welding from other side.
Preheating / post-heating of surfaces / stress relieving of weld joints is
carried out wherever necessary as per technical requirements.
5.7 After root run completion of welding dye penetrant testing is carried
out and corrective action taken.
5.8 Wherever circumferential welding is involved, welding as per sketch
no. 1 is followed for making root run.
5.8.1
5.8.2
5.8.3
After this, welding may done starting from two or four points and
proceed continuously. In other joints skip / step welding as
shown in sketch no. 2 may be followed to minimize deformation
of equipments.
5.9
5.10 All site weld joints of stayring and spiral casing are radiographed or
UT done as per technical requirements of concerned drawing.
5.11 After completion of site welding and grinding painting of effected
areas is to be done.
5.12 In case welding is provided in pipe works, edge preparation and
welding is carried as per drawing requirements.
6.
ASSEMBLY OF EQUIPMENTS
9.1
9.2
9.3
9.4
9.5
Check for PO number, assembly match mark and axis marking for
each assembly.
9.6
Ensure that individual components are cleaned & are free from burrs
and scratches.
9.7
9.8
9.9
9.10 Blow compressed air to oil and grease ports, load grease ports with
grease and plug them temporarily.
10. CONFIRMATION BEFORE STARTING ERECTION / ASSEMBLY
WORK
10.1 Confirm availability of all tools and tackles required for erection
works.
10.2 Confirm
availability
of
reference
drawings
and
technical
B.
1.
2.
3.
4.
5.
6.
Store gas cylinders away from "Sources of Heat" Over Furnace, direct
sun rays.
7.
8.
9.
10.
Ensure against leakage of gas from torch, hose valves Regulators etc.
Use proper pipe clips. Periodical checking of pressure gauges of
regulator to be done.
11.
No flammable material like Petrol, Oils Dyes Acids Enamel paints and
Varnishes etc, be lying in the area where cutting or welding is being
done.
(c)
Lifting Tackles
1.
2.
3.
4.
5.
Periodic testing of 'D' shackles, turn buckles, Pull lifts and chain pulley
blocks be done.
6.
Avoid wire ropes coming in contact with sharp edges while lifting.
(D)
Cranes
1.
2.
Do not keep the load suspended for more time than absolutely
required. For this, plan your activity well in advance.
3.
4.
5.
6.
7.
(E)
1.
2.
3.
4.
5.
6.
7.
8.
F.
1.
Never add water to Acid for making dilute solution. Always add Acid to
water.
2.
Never handle any acid or alkali with bare hands and without protection
to eyes.
3.
Use acid proof rubber gloves, gum boots, rubber aprons and goggles
as per Job requirements.
4.
SEQUENCE OF ERECTION
A.
B.
C.
D.
D.T. Cone
E.
F.
Stay ring
G.
Spiral Casing.
H.
I.
J.
Pressure Testing & Dismantling Test Cone & Cylinder Runner envelop
& Matching Piece. (Make up piece)
K.
Concreting
L.
M.
N.
O.
Runner assembly runner & shaft assembly pr. test. Trial assembly of
G.V with pivoting & outer Top Cover.
R.
Lowering of Runner & Shaft assembly with Inner top cover final assy, of
Guide apparatus.
S.
T.
U.
V.
W.
X.
Y.
Z.
2.6.1
1.
EL 519.60m (present)
EL 524.256 m (future)
EL 511.16m
30.55m (present)
35.206m (future)
18.91m
5. Rated head
26.60m (present)
6. Direction of rotation
EL 504.50m
8. Type of turbine
FULL KAPLAN
To be furnished
252.48 cumecs
(overload capacity)
11. Rated speed
115.38 rpm
5650 mm
7m
7.80 m
25 m
7 sec
15 sec
35%
13 sec
40%
(% of rated speed)
19. Range of speed
50 5 Hz
adjustment device
20. Speed droop control :
(a) Permanent
0 to 10%
(b) Temporary
0 to 100%
38.95m
47.42 m
EL 466.72m
EL 490.00m
EL 484.90m
EL 482.66
100%
G. V. OPENING 0 (mm)
555 10
In degree
50
SERVOMOTOR STROKE IN MM
811.3
654.7
RING
A1.
A2.
A3.
Generator Alignment
A4.
A5.
A6.
A7.
A8.
A9.
Sl. No
DESCRIPTION
PAGE NO:
23
2.
24
3.
25
4.
Draft Tube
26
Embedded Parts
Embedded Pipe in First Stage
(A)
Pre-Erection Checks.
(i) Check for availability of all the items as per relevant drgs & bill of
material and clean them.
(ii)
(B)
Erection.
(i)
Pipes to be erected.
(a)
(b)
(iii)
(iv)
(v)
(vi)
2.
3.
4.
5.
6.
7.
8.
9.
Pier Nose
1.
Lower Pier nose assembly using winches wire ropes or suitable crane
then check level and elevation.
2.
3.
4.
5.
Fixing of Anchors.
6.
7.
(a)
Vertically 1 .mm/metre.
(b)
2.
3.
4.
5.
Arrange all bottom, top, left side, right side segments and assemble
them complying with elevation w.r.t. relevant drgs.
6.
7.
Check dimension elevation, matching and then clear for full weld.
8.
9.
10.
Flush grind final run, align, tighten, H.D. Bolts and Turn buckles lock,
erect drain box assembly & connect DT drain pipe & weld.
11.
Lower two bottom cone segments, align with DT liner and Tack weld.
2.
3.
4.
Check alignment of cone w.r.t. X & Y axis within 2 mm. Top center of D.T.
cone to be in line with D.T. liner center within 2 mm.
5.
Measure the inner diameter of cone at the top. If it is not as per drg.
correct it.
6.
7.
Weld the joints as per relevant standards and dye test the root run.
8.
Release for concreting up to casing of piers for spiral casing and stay
ring.
SL.NO
DESCRIPTION
PAGE NO
STAY RING
29
2.
SPIRAL CASING
30
3.
RUNNER ENVELOP
31
4.
PIT LINER
32
STAY RING
(ii)
(iii)
(iv)
(v)
Establish center line (x, y Axis) & Datum elevation given by the civil
wing.
(vi)
(B) ERECTION
(i)
(ii)
Assemble in service bay and heat and tighten the Joint bolts to achieve
elongation as per drawing.
(iii)
(iv)
Lower the Stay ring on stools, so that stay ring pedestal are resting on
the stool. Align center & level with respect to station, Center Line, using
hydraulic Jacks/Mechanical Jacking screws.
(v)
(vi)
(vii)
(viii)
SPIRAL CASING
(A) PRE-ERECTION CHECKS.
(i)
(ii)
(iii)
Check and prove threads on holding down, bolts & jacking bolts
& other hardware.
(iv)
(B) ERECTION
(i)
Assemble the spiral segments as per drawing & ensure that gap
at joints in axial or radial direction is 2 to 5m.m
(ii)
Match the spiral members with top & bottom contour of stay ring
& center line marked on spiral member with reference to center
line of stay ring ( 2mm).
(iii)
(iv)
Dye check the weld seams for any surface defects in the plate.
(v)
Back gouge, grind & dye check for seal run, complete the
sealing run.
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
(xiii)
(xiv)
2.
Check diameter.
B. Erection.
i.
Runner Envelope to be lowered, after lowering for Ist out before stay
ring.
ii.
iii.
iv.
v.
vi.
vii.
PIT LINER
ERECTION
A. LOWER THE PIT LINER SEGMENTS
1. The mechanical surfaces for fixing the servo motors are equidistant from X
& Y axis (with tolerance as per drawing) & are vertical. 1 mm. per meter
2. Top dia of pit liner ( 5 mm)
3. Welding to requirements as per drawing.
4. Welding of anchor plates.
5. Installation of pipes / Pipes sleeves for routing of air, water and other pipe
lines. Also check that embedded pipe carrying in this state of concreting
are installed and the free ends are blanked off by welding metal plate.
Ensure placement of sufficient sleeves for routing cables etc also.
Ref Drawing: Installation of pit liner Drg. No. 02020714201
SL. NO
1.
DESCRIPTION
2.
3.
4.
5.
6.
7.
8.
9.
Installation. of G V. servomotor
10.
Guide Bearing
11.
Shaft seal
PAGE NO.
12.
Oil-Header
13.
Governing Equipment
14.
RUNNER ASSEMBLY
1.
2.
3.
Check the match markings during dismantling (if the runner is received
at site in assembled condition).
4.
5.
m) Measure and record the clearance between runner hubs & blade, it
should be as per drawing value.
n) Perform testing of the Runner as per test procedure technical data
provided in the drawings supplied by manufacturing unit.
Drawing to be referred
1. Tools tackless for runner shaft drg. No. 02045114201
2. Runner assembly drg. No. 02040714201
3. Shaft arrangement drg. No. 02050114201
4. Arrangement of all tubes of runner servomotor drg. No. 2050314201
5. Testing devices for runner & shaft drg. No. 02045214201
6. Log sheets:
1) Elongation of fitted bolts between runner & shaft L-06
Test certificate for KAPLAN runner assy, L-05.
RUNNER ASSEMBLY
Overhauling, Shaft assembly, Hyd. Testing
A. KAPLAN RUNNER
1. Runner of a Kaplan turbine is dispatched to site, fully assembled or partly
assembled and partly loose depending on its overall size / transport
limitations. Partly assembled runner comprise of hub, turning mechanism,
piston, runner blades, bottom cover etc. The loose components may be
runner servo tubes, piston rod, cone and other hardware.
2. Check all the materials as per drg & all tools available for carry out
overhauling.
3. Carry out dismantling, overhauling of partly assembled components,
hydraulic testing of completely assembled runner at site in accordance
with technical requirements, to ensure trouble free operation.
4. Carry out trial lowering of assembled runner in to the runner chamber if
called up before its assembly with shaft to check and ensure clearances
between runner blades and runner chamber with runner blades pulled out.
In the event of clearances being less than those specified in the drawing,
correction is done either by grinding the tip of runner blades / runner
chamber in the complete zone of runner blades operation (i.e. close to
open & open to close).
B. OVERHAULING ASSEMBLY
1.
2.
3.
4.
5.
Fix bottom cone as per match mark & perform tightening & locking.
6.
Turn the portion of the runner & lower it over the platform made for
runner blade fixing.
7.
Carry out assembly of runner blade with cup seals as per instruction
given in drg.
2.
Check the mating surface of turbine shaft & runner for trueness.
3.
Check & ensure the holes of coupling bolts in runner & shaft and
coupling bolts are as per drg.
4.
Prepare shaft in line with general guidelines and check trueness of all
machined surfaces.
5.
Check and prove bedding of guide bearing pads with guide bearing
journal of shaft, with shaft in horizontal position (Ref. Instructions for
bedding of pads) before runner shaft assy start.
6.
Carry out cleaning, acid pickling, neutralization and oil rinsing interiors
of oil servo tubes. Insert the lower part of servo tube in shaft bore before
runner shaft assy start.
7.
Turn the shaft to make it vertical along with servo tube (runner servo
tube is suspended with chain pulley blocked to the same crane hook
connected to shaft).
8.
9.
Install O-seal, lower the shaft and carry out assembly of shaft with
runner, coinciding the match marks. Install all coupling bolts, tighten to
required stress / elongation as per technical requirement & lock the nut.
10.
Check soundness of runner shaft assembly joint with the help of 0.03
feeler gauge. In the event of correct assembly, feeler gauge will not
pass.
11.
Cover the open end of servo tube temporarily to avoid entry of foreign
materials in to the system.
12.
Prepare FQA log sheet for elongation tightening & completion of runner
shaft assy.
2.
Carry out laying and connection of pipes as per the scheme of testing
supplied by the manufacturer.
3.
Note : Oil leakage is not permitted, through the cup seals of runner blades.
4.
5.
Note : Oil leakage is not permitted, through the cup seals of runner blades.
Reference Drg. No.
1) 02040714201
Runner assembly
2) 02050114201
shaft arrangement
3) 02045114201
4) 02050314201
5) 02045214201
Runner shaft assembly is lowered along with turbine top cover. Runner
shaft assembly is supported on top cover with a suitable supporting
bracket fitted at the seat of turbine guide bearing. Turbine guide bearing
skirt rests over this bracket.
2)
3)
Carry out leveling at turbine shaft flange and centering of runner with
runner chamber.
C.
2)
3)
Check the matching surfaces of pivot ring for any burr / foreign materials.
Clean, if any.
4)
Ensure availability of proper tools slings etc. for erection of pivot ring.
5)
6)
Lift the pivot ring individual segments and lower them on wooden pegs
kept on the runner envelop / stay ring, for their assembly.
7)
Lift the assembled pivot ring, and lower them over the cleaned resieng
surface.
8)
9)
2)
3)
4)
All flanges and threaded holes of stay-ring are cleaned and surfaces
deburred.
5)
6)
2)
3)
4)
5)
6)
Install all holding down bolts of lower ring and complete tightening.
7)
8)
Assemble four upper guide vane bush housings, 90 degree apart on top
cover. Lift the top cover precisely leveled with the help of turn buckles
and crane and lower it on stay-ring.
9)
Position the top cover using dowels and reference match marks.
10) Install alternate holding down studs of top cover and install all upper
guide vane bush housing (thin layer of grease on guide vane journals
and bush housing before installation).
11) Check and ensure free turning of all guide vanes. While tightening the
nuts of holding down studs till tightening of all nuts of top cover is finally
completed.
12) Bring all guide vanes to close position, to check and ensure the
clearances of guide vanes with top cover at leading and trailing edges
are as per drawing requirements. In case of deviation from the drawing
requirements, corrective action is taken wherever required.
13) Carry out bedding of guide vanes and correction if need be.
14) Lower inner top cover & align it.
15) Complete reaming, doweling of lower ring and inner top cover & outer
top cover.
FINAL ASSEMBLY OF GUIDE APPARATUS
PRE-ASSEMBLY CHECK
1)
Dismantle and remove all the components assembled for trial assembly.
2)
Check the rubber cup seals and O-seals do not carry any cracks and are
not de-shaped.
3)
Install cup seals and retaining rings on lower bush bearing of guide vane
and ensure that retaining ring does not interfere with lower collar of the
guide vane. In case of interference, the retaining ring shall be suitably
machined.
4)
5)
Install rubber seal of top cover on stay-ring & complete the assembly of
top cover with stay ring using dowers pins & fasteners ( to ensure proper
assembly of top cover stay ring ,check gap between top cover & stay ring
flange by 0.03 mm feeler gauge ,which should not pass).
6)
Assemble guide vane bush houses with seals and check free turning
movement of each guide vane. (ensure bush house installation with
reference to grease port for pipe connection)
7)
Guide vane should move freely when turned by one person by using
spiral spanner supplied as erection device by the manufacturer. After
installation of bush.
8)
Lower runner assembly with inner top cover runner shaft assembly.
Note : Allowable tolerance in centering 0.1 mm Leveling with 0.03
mm/met.
9)
10) Check and ensure centering of runner w.r.t. Lower labyrinth on lower ring
is within the specified limits.
11) Install regulating ring and servo motors (refer instructions for installation
of servo motors of different variants, described separately).
12) Install link mechanism and adjust guide vane end clearances, bedding
clearance and clearance between lever and lever stopper / collar.
13) Check free turning movement of all guides vanes from full close to full
open position.
14) Position regulating ring to close of guides apparatus complete centering
and provisional locking.
15) Install connecting rods of servomotors with regulating ring and carry out
pre-stressing of guide apparatus mechanism (refer instructions described
separately).
Note : After final assembly of guide apparatus, grease and lubricate all
bearings and check for easy turning movement of guide apparatus
mechanism by applying oil under pressure in the servo motors. The
complete mechanism should turn freely at oil pressure not more than 5
kg/sq. cm or as indicated in drawing. In case guide apparatus fails to turn
at this pressure, its causes must be investigated and removed.
16) Prepare FQA log-sheet for completion of guide apparatus assembly in
accordance with field quality checks.
PRE STRESSING OF GUIDE APPARATUS MECHANISM
8.2
Plot the graph from the values obtained check that the curve nearly
matches with the design values.
components / joints.
2) Check the cup seal O rings of servomotors for any cracks or damage.
Check the interference of cup seals I. D. with sleeve.
3) Clean thoroughly all parts and inside surface of piston and cylinder with
solvents like diesel / petrol check the surfaces of piston, cylinder, piston
rings, bushes etc. for any scratches.
4) Use new cup seals and prepare O ring if assembled ones are worn
out and if replacement is necessary.
5) Assemble the covers using O ring. Fasten the covers by tightening
the studs and nuts.
6) Insert the piston assembly in the cylinder in vertical position, taking
care to keep the slot portion of piston towards oil ports. Lubricate
cylinder surface profusely with turbine oil as soon as piston rings have
entered the cylinder remove clamp, used for pressing the piston rings.
7) Assemble the cylinder cover using cup seals. Fasten the cover with
stud nut. Locking of nuts to be carried out only after satisfactory
hydraulic testing, & after checking the opening and closing of
servomotor and checking the seals are intact.
B) INSTALLATION
1.
Check and clean the base plates mounted on pit liner. Check
vertically.
2.
3.
4.
Align both the servomotors to drg. Dimension. Keep the piston rods of
both servomotors in fully closed position (i.e. piston touching the
respective cylinders ends).
5.
Check the threads of piston rod. If necessary clean and dress with
triangular smooth file.
6.
7.
Assemble the piston rod and connected rod initially, keep 25 mm gap
between piston rod and connecting rod.
8.
9.
Maintain the distance 1985 of G.V. servo cylinder (Not of piston rods /
connecting rods) and level the servomotor.
10. Now if the gap between mounting plate and plate of pit liner is less
than 3mm weld mounting plates directly to pit liner without using strip,
GV servomotor LH
L-10
02030314201
02031114201
Pre-erection.
Thoroughly clean all parts and joint faces of bearing oil sump. Use
engineers blue on one face, tighten the joint faces and check the
bedding. If necessary scrap the face. Filler gauge can be used to find
out the gap.
ii)
Clean the bearing pads with solvent like petrol and white spirit. Check
their bedding with the bearing journal of the shaft. If necessary
Scrapping can be done. Also check the bedding of Disc. Check that
stud has spherical curvature where it is pressing the disc.
iii)
iv)
v)
Check the working of oil level indicator in Separate oil container out
side.
vi)
Apply liquid sealing compound (hold tight at joint faces of the Bearing
oil sump. Bottom ring)
(ii)
Install the rubber o" rings and position the bearing housing matching
with unit axis marked on the top cover and bearing housing.
Center the center piece with respect to turbine shaft journal (with runner at
centre) Tighten nuts and washer.
(iii)
(iv)
Fix studs with holdtite. Assemble the two halves of bearing housing,
1.2
Assemble housing of isolating seal, place the isolating seal and housing
and cut the extra length of seal. Test the isolating seal by air as per
chemical requirements of drawing and confirm expansion of seal under
air pressure.
1.3
Check and grind the top surface of cups, if any projecting over and
above the surface of ring supporting the working seal.
2. ERECTION
2.1
Assemble base plate / housing of isolating seal with top cover along with
O seal, maintaining clearances between rotating and stationary parts
as called in drawing (use liquid compound / hold tite at the joints of
housing).
2.2
Install and join isolating seal using suitable adhesive such as anabond /
elfy.
2.3
2.4
Install cups and lip-type rubber working seal and join it with suitable
adhesive and complete the assembly of cover plate.
2.5
Joints of rubber working seal are made taking into account the
direction of rotation of the machine.
ii)
2.6
Carry out drilling, reaming, doweling of turbine shaft sealing frame with
top cover.
2.7
Oil header is intended to supply the oil under pressure from oil pressure
unit to runner servomotor through a set of concentric pipe lines installed
in turbine, generator shafts. The leakage from the runner passes to
pressure pumping set through the bore of turbine, generator shaft and a
oil guide / deflector installed on shaft. Oil pressure for opening closing of
runner blades is supplied through main slide valve of runner installed in
HMC of governor. The runner feed back system & the indicator showing
the position of runner blades are also mounted on the oil header. Oil
header is assembled with runner shaft logged after alignment & center
of runner.
4. PRE ASSEMBLY
4.1 Check individual component of oil header is prepared to technical
instruction.
4.2
4.3
Place oil header assembly upside down and ensure the movement of
pipe line assembly, in the oil header bush is smooth.
4.4
Check and record the diameters of bush and pipe line assembly. Check
oil deflector items machined surfaces are true and check level and
surface finish exciter shaft for trueness (where oil deflector is
assembled).
After assembly of runner, shaft and inner top cover in erection bay
check horizontality of the upper flange of oil tube (lower). Upper flange
of oil tube (lower) should be parallel to turbine shaft coupling face.
5.2
Lower the assembly of runner, shaft and inner top cover along with oil
tube (lower) in the turbine pit (preferably after testing of runner on
erection bay).
5.3
Insert middle tube inside generator shaft in erection bay and then lower
in the pit keeping oil tube projected by 200 mm approx. below
generator shaft to facilitate coupling of tubes.
5.4
5.5
Assembly oil tube (upper), check the horizontality of its top flange and
throw of spigot.
5.6
5.7
Lower the assembly of central pipe and pressure box. After assembly
with upper tube, check throw of central pipe and pressure box.
5.8
The allowable value of throw for point no. 4, 5, 6 and pressure box is
preferably 75% of the diametral clearance at pressure box bearing, and
in no case it should exceed the value of diametral clearance.
5.9
The allowable value of throw for central pipe is preferably 75% of the
diametral clearance at central pipe bearing, and in no case it should
exceed the value of diametral clearance.
5.10
If the throw is more than the value mentioned in Para 8 & 9 above,
correction to be done in respective flange face by suitability scraping or
using shims taking care of O seal grooves.
5.11
Assembly oil bath and oil guide as per drawing, centralize oil bath to
get the uniform labyrinth clearances.
5.12
Lower oil header body carefully in balanced condition taking guide from
central pipe in such a way that there is no radial pressure or bending
effect on central pipe. If the spigot between body and oil bath does not
match, loosen the spigot suitably by grinding and assembly body to oil
bath.
5.13
After checking free rotation and stroking of oil tubes, dowelling of oil
header body and oil bath to be carried out.
5.14
In extreme position of runner blade stroke (fully open and fully close),
rotate the machine at very slow speed for checking any fouling
between stationary and rotating components.
(ii)
(iii)
Prepare all the "0" seals and check for damage/crack, if required
replace it.
After assembly of Runner, Shaft and Inner top cover in erection bay
check horizontality of the upper flange of oil tube (lower). Upper flange of
oil tubs (lower) should be parallel to turbine shaft coupling face.
2.
Lower the assembly of Runner, shaft and Inner top cover along with oil
tube (lower) in the turbine pit (Preferably after testing of Runner on
erection bay).
3.
Insert Middle tube inside Generator shaft in erection bay and then lower
in the pit keeping oil tube projected by 200mm approx. below generator
shaft to facilitate coupling of tubes.
4.
Assemble oil tube (upper), check the horizontality of its top flange and
throw of the spigot.
6.
Lower and assemble generator tubular shaft with Generator shaft, check
throw of spigot in generator tubular shaft and horizontality of top flange.
7.
Lower the assembly of central pipe and pressure box. After assembly
with upper tube, check throw of central pipe and pressure box. .
8.
The allowable value of throw for point no. 4,5,6 and pressure box is
preferably 75%. of the diametral clearance at pressure bob bearing , and
in no case it should exceed the value of diametral clearance.
9.
The allowable, value of throw for central pipe is preferably 75%. of the
diametral clearance at central pipe bearing, and in no case it should
exceed the value diametral clearances.
10.
If the throw is more than the value mentioned in Para 8 & 9 above,
correction to be done in Respective flange face by suitably scraping or
using shims taking care of "O seal grooves.
11.
Assemble oil bath and oil guide as per drawing, centralize oil bath to get
the uniform labyrinth clearances.
12.
Lower oil header body carefully in balanced condition taking guide from
central pipe in such a way that there is no radial pressure or bending
effect on central pipe. If the spigot between body and oil bath does not
match, loosen the spigot suitably by grinding and assemble body to oil
bath. Grinding can be carried out since there are 4 Dowels of 16mm in
addition to 16 studs of nuts of M20 for holding the body with oil bath
which keep the joint tight even in running condition job the Machine.
13.
After checking free rotation and stroking of oil tubes, dowelling of oil
header body and oil bath to be carried out.
14.
In extreme positions of Runner blade stroke (fully open and fully close),
rotate the machine at very slow speed for checking any fouling between
stationary and rotating components.
15.
16.
GOVERNING EQUIPMENT
(i)
(ii)
Pressure Receiver.
(iii)
(iv)
Check all the pockets of foundation are as per drawing. Ensure sides of
these pockets are slightly rough for proper bondage of concrete.
(ii)
(iii)
(B) Erection.
(i)
Lift the complete P.P. Set assembly on 4 equal wire Ropes, using eye
bolts in fairly levelled condition
(ii)
Install the P.P. Set as per drawing dimensions. Check the elevation at 4
places. Ensure no gap exists between supporting brackets and
concrete.
(iii)
(iv)
(v)
(vi)
(ii)
Remove manhole door and inspect for any rusting from inside surface
or foreign material during Transportation. Check the paint condition
from inside.
Place the manhole door in the position if required replace the gasket.
(iii)
(B) Erection.
Lift the pressure receiver in balance condition and assemble it on the
(i)
(iii)
Mount all the fittings on receiver and prevent them from any damage
(Glass parts/pressure gauges).
Pressure test the receiver with air and check leakage through any
(iv)
fittings.
Hydro Mechanical Cabinet & Runner Control Mechanism
(A) Pre-erection.
(i)
(ii)
(iii)
Check the location and size of the pockets are as per drawing
dimension.
(B) Erection.
(i)
Install the hydro mechanical and electrical cabinet as per the drawing.
(ii)
(iii)
Check the verticality of the cabinets by plum bob and also check level,
02210114201
02200114201
02085014101
02083614101
Check that all items are available and are in sound condition.
(ii)
(iii)
the drawing.
Touching of wire rope with any bracket, tube etc. is not allowed.
(iv)
(vi)
(vii)
Wire rope after installation should be in tension (not loose, to avoid any
back lash)
(viii)
ii)
iii)
iv)
v)
Install pressure gauges on draft tube cone, penstock, spiral case and
other instruments as per layout drawing.
Note :
1. Carry out hydraulic testing of pipelines wherever called for.
2. Ensure calibration of all metering instruments prior to putting them
in service.
Shear pin is a weak link between strap and guide vane lever and
fails in the event of blocking or jamming of guide vanes. With the
failure of shear pin guide vane becomes free of its turning
movement and strap alone moves and opens the contacts of the
limit switch to initiate a warning signal of shear pin failure at UCB.
The limit switches are connected in series with normally closed
contact.
C) ERECTION
i)
Install all base plates of unit switches, strikers and clamps as per
layout details.
ii)
iii)
iv)
Guide apparatus
AUXILIARIES
1
Note: For erection of all the above Equipment refer the respective drawing &
documents of the equipment. PP Set, HMC, RCM, Pr. Receiver.
ALMATTI HEP
TURBINE DRAWINGS 55 MW
UP DATED AS ON 14/06/2004
Sl. No
Drg. Title
Drg. No.
T1
STATION LAYOUT
0-200-00-14201 03
03
T2
01
T3
02
T4
02
T5
1-201-00-65602 01
01
T6
KPCL/ADPH/DT
L/55-01
02
T7
EXTENDED PORTION DT
KPCL/ADPH/DT
LINER (5 X 55 MW) SUPPORT L/15-04
STRUCTURE ARRANGEMENT
01
T8
0-201-11-14201 02
01
T9
01
T10
0-202-08-14201 02
03
T11
DETAILS OF PIERS
0-202-08-14203 00
01
T12
0-211-01-14201 00
01
T13
DETAILS OF PIERS
0-202-09-14201 01
02
T14
02-02-01-14201 00
02
T15
0-202-01-14201 01
02
T16
SPIRAL CASING
0-202-02-14202 00
03
T17
PARTITION PLATES
1-202-02-14201 00
01
T18
0-202-02-14201 02
03
T19
0-202-52-14201 01
01
CHECK
T20
01
T21
RUNNER ENVELOPE
INSTALLATION
0-202-06-14201 00
02
T22
0-202-07-14201 01
02
T23
02
T24
01
T25
0-210-09-14201 00
01
T26
GUIDE APPARATUS
0-203-01-14201 01
01
T27
0-204-51-14201 00
03
T28
RUNNER ASSEMBLY
0-204-07-14201 01
03
T29
SHAFT ARRANGEMENT
0-205-01-14201 00
01
T30
ARRANGEMENTS OF OIL
TUBES OF RUNNER
SERVOMOTOR
0-205-03-14201 00
02
T31
0-204-52-14201 00
01
T32
INSTALLATION OF G. V.
SERVOMOTOR
0-203-11-14201 00
01
T33
G. V. SERVOMOTOR L.H
0-203-02-14201 01
02
T 34
G. V. SERVOMOTOR R.H
0-203-03-14201 01
02
T35
0-221-01-14201 02
01
T36
ARRANGEMENT OF
PRESSURE RECEIVER
0-220-01-14201 03
01
T37
HYDRO MECHANICAL
CABINET
0-208-50-14101 00
01
Check
T38
RUNNER CONTROL
0-208-36-14101 00
02
MECHANISM
T39
0-210-18-14201 00
03
T40
0-208-48-14201 00
02
T41
0-299-20-14201 00
03
T42
T43
0-210-17-14201 00
02
T44
INSTALLATION OF
FLOWMETER EQUIPMENTS
AND ITS PIPING
1-210-16-14201 00
01
T44
OIL HEADER
0-205-02-14201 00
02
T46
01
T47
ARRANGEMENT OF GUIDE
BEARING
02
T48
T49
INSTALLATION OF RAILING
AND PLATFORM IN TURBINE
PIT
0-210-11-14201 01
02
T50
0-210-51-14201 00
01
NA
0-206-01-14201 00
NA
ANNEXURE
LOG SHEETS
Description
Log Sheet No
L-01
L-02
L-03
L-04
L-05
L-06
L-07
L-08
L-09
L-10.
L-11
L-12
L-13
L-15
Page No.