Bharat Heavy Electricals Limited Doc No.

BHEL/LTP/01
NPCIL
Date: 11/11/2016
TGPP for KAPP (3&4)
Rev No: 00
PS-WR

Procedure for Load testing of

HP/LP turbine rotor lifting beam
 Bharat Heavy Electricals Limited Doc No. BHEL/LTP/01
NPCIL
Date: 11/11/2016
TGPP for KAPP (3&4)
Rev No: 00
PS-WR

Procedure for Load testing of HP/LP turbine Rotor lifting beam

Work Order No: CMM/MEQ/23-40-2-1024/PO-6055 DT-31/03/2011

BHEL DOCUMENT NO: BHEL/LTP

NPCIL PROCEDURE REG. NO:

DATE:

PREPARED BY: AMIT VERMA

BHEL ENGINEER

SUBHASHIS CHATARJEE
NPCIL EXECUTION

REVIEWD AND APPROVED BY: B.L.SAHU

ACE(TG)
 Bharat Heavy Electricals Limited Doc No. BHEL/LTP/01
NPCIL
Date: 11/11/2016
TGPP for KAPP (3&4)
Rev No: 00
PS-WR

Rev-00

REVISION CONTROL SHEET

Document no: BHEL/LTP

Title: Procedure for load testing of HP/LP turbine Rotor lifting beam

REVISION SHEET
Rev no. Description Prepared by Reviewed by Approved by
of Revision Sign & date Sign & date Sign & date
 Bharat Heavy Electricals Limited Doc No. BHEL/LTP/01
NPCIL
Date: 11/11/2016
TGPP for KAPP (3&4)
Rev No: 00
PS-WR

INDEX

Clause Description Page no.

1.0 Scope 05 to 05

2.0 Purpose 05 to 05

3.0 Applicability 05 to 05

4.0 Reference 05 to 05

5.0 procedure 05 to 05

6.0 Acceptance Criteria 06 to 06

7.0 Records and documentation 06 to 06

8.0 Distribution 06 to 06
 Bharat Heavy Electricals Limited Doc No. BHEL/LTP/01
NPCIL
Date: 11/11/2016
TGPP for KAPP (3&4)
Rev No: 00
PS-WR

1.0 Scope:
This Test Procedure is to be used for Load Testing of HP/LP turbine rotor Lifting
Beam for 700 MW KAPP Nuclear Power Projects.
2.0 Purpose:
This procedure gives general guidelines and instruction for load testing of rotor
lifting beam.
3.0 Applicability:
This procedure is applicable to BHEL-KAPP 3 & 4 Construction site.
4.0 Reference:
This procedure is referring to following procedure.
 Atomic Energy Regulatory Board
 BHEL HSE Manual
 Bhopal procedure guidelines/INDO/DOC/10
 Drawings
5.0 Procedure:
The test is required to proof the strength of lifting beam along with its
accessories (Slings, D-Shackles etc).
The procedure for load testing shall be as under.
1. Place the box girder on two small box supports to raise it above surface level.
2. After load and deflection test the lifting beam joints shall be examined by DP test,
if found any abnormality the repair/rectification shall be done and after repair the
beam shall be tested again for load and deflection test.
3. The strength and deflection test can be performed at different points of lifting beam
by adopting the method as mentioned above.
4. Load Test of Beam at 100% capacity Safe Working Load i. e. 78 MT) :
Take two set of Loads i.e.40 MT at one end and 38MT at another end of beam.
and then for proof load we will take 150% of SWL in two sets whichever one side is
60MT and other side is 57MT.
Load Test of Beam at 150% capacity (Proof Load i. e.117 MT):
Take two set of Loads i.e.60 MT at one end and 57MT at another end of beam.
5. Wrap the weights using wire rope ceiling and D-shackle to provide local lifting
facility.
 Bharat Heavy Electricals Limited Doc No. BHEL/LTP/01
NPCIL
Date: 11/11/2016
TGPP for KAPP (3&4)
Rev No: 00
PS-WR

6. The wrapped weights shall connect with one end of nylon belt supplied with the
beam and another end of same nylon belt shall be connected to Lifting beam.
7. Likewise two nylon ropes will get connect with the beam at both ends to lift the
loads.
8. The beam shall get connect with the Main Crane Hook with wire rope slings.
9. Load will be lifted for 15 Min freely in the air.
10. To measure the deflection at particular position, initially measure the distance of
particular w.r.t. surface of fixed box girder and after the application of load again
measure the distance. The difference in the measured value will be the deflection at
that particular point.
11. After load test performance, all welds shall be checked by DPT. All welds are to be
intact & no abnormality should be found.
12. Schematic Arrangement for Load Testing: - Details is shown in attached Drawing.

6.0 Acceptance Criteria:

Load Test is to be done at proof load (1.5 Times SWL) for 15 min.
 Maximum deflection at full load shall be span/600mm.This is as per IS:807-2006.
 No permanent deformation is accepted.
 No crack will be accepted during DPT after load testing.

7.0 Records:
Records for Load Test and DPT test will be prepared.

8.0 Distribution:

Npcil Mech/TG
Npcil QA
Npcil safety section
Npcil CE
Bhel Safety section
Bhel Mech/TG
 Bharat Heavy Electricals Limited Doc No. BHEL/LTP/01
NPCIL
Date: 11/11/2016
TGPP for KAPP (3&4)
Rev No: 00
PS-WR