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Presented by
Sudhir Chiplunkar
1. Discuss various bolting elements commonly used in Turbine couplings
2. Cover the pros and cons of these various bolting elements
3. Introduce SKF Supergrip Bolt & Line Boring service
4. Advantages & Global references
5. Financial impact of our solution to NTPC
This is perceived as
“Normal”
Stuck bolting, material pick‐up is common
High Down time when coupling on critical path
Skilled manpower required for line boring
Reliability of scheduling is questionable because of bolting issues.
Safety issues if “Stuck bolt”
TORQUE TRANSMISSION:
1. Friction Connection
• Large axial pre-loads generated by the bolting elements
• Pre-loads press coupling halves together to create friction forces in the contact plane (split
line)
2. Positive Connection
• Torque transferred by touching contact planes
• Usually indirectly through the bolting elements
• Often close fitted bolts are used
• These bolting elements transmit torque (in shear) by contact pressure between the bolting
elements and the bores of the coupling flange bolt holes
Friction couplings with through bolts are commonly used and tend to be the
Least costly. The through bolts (1) are inserted through holes (bores) in the
coupling halves and are pre‐loaded axially with nuts (2) on both ends to
create the friction connection in the contact plane.
The image below shows the load carrying mechanism of the flange
couplings with through bolts. The black arrows indicate the circumferential
loads in the coupling halves resulting from the torque to be transmitted. The
friction forces in the contact plane are depicted as white arrows.
Fitted bolts are similar to the through bolts except that the fitted bolt fills the
bore except for a few hundredths of a millimeter. As a result, the accuracy of
the parts and surface quality must be much higher. The fitted bolts are
commonly tailored individually for every bore; thus the fitted bolts are initially
more expensive than through bolts.
Almost all turbines in India has these types of bolts
Theoretical perception as we
maintain stringent tolerances on Bolt
& Hole is that we have fitted bolts
Even without considering Line boring issues, Size control … We have
Randomly oriented clearance Bolts due to Stretching (Poisson’s Ratio )
When the coupling is subjected to the torque, this clearance will allow for a
small slippage of the flanges. As the clearance varies between the holes,
some of the bolts will be subjected to a higher torque than others. The
flanges will be pinching the bolts on two sides of the hole. When the
Preload is released this pinch will be increased at two sharp corners of the
hole. If then an attempt to remove the bolt is made, the risk for galling and
other damages is further increased.
Radial backlash is necessary for function of fitted bolts which in turn creates
non‐uniform load distributions
Repeated micro‐movements in the connections under dynamic/ transient loads
Radial backlash can cause the fitted bolt to angle itself inside bore
Stuck bolts/studs common, often have to be destroyed to remove
No Assurance of re‐establishment of Concentric positioning of Rotors – Higher
Run out setting time
Excessive down time, large monetary losses
Picture and chart show the impact on the flange stresses as a result of the
variation in fit between bolt and hole, going from a loose clearance fit to a tight
interference fit
With a reduction of the clearance between the bolt and hole , all the way through
a solid interference fit, stress concentrations in the bolt are clearly reduced.
The variation in clearance is also affecting the bending stresses in the bolt.
The bolt with the biggest clearance has a significantly higher stress level.
Turbine
Coupling
bolts
A bolt with a tapered shank (2) is pulled into a tapered sleeve (3) by a nut
(4). The tapered sleeve expands radially creating an interference fit inside
the bore. A second nut (1) is used to axially pre‐load the coupling. The
resulting clamping force creates an additional friction connection in the
contact plane.
Mounting;
In a fraction of time
Just a matter of a few
minutes per bolt!
Without risk of stuck bolts!
Dismounting;
Even lesser time to
dismount than it took for
mounting.
Without risk of stuck bolts!
• Reduced Downtime
• Shorter outages
• Accurate Planning
Supplied with all major turbine manufacturers:
GE; Siemens/Westinghouse; Alstom; Ansaldo; Skoda; LMZ;
Hitachi; MHI; Toshiba; Fuji; Shangai and Harbin Turbines;
Installed in Power Stations Worldwide:
From 100 MW coal/oil/gas Thermal Plants to +1000 MW Nuclear Power
Stations!
Total Turbines working with Supergrip bolts
More than 2300 ...
This calculation is for only capital overhaul, if decoupling required during AOH
additional saving guaranteed
For SGB’s CRO gets reestablished because we create dowels rather than loose fitted
bolts.
2016-02-19 ©SKF Slide 26 [Code]
SKF [Organisation]
What this can deliver to NTPC
No. of Units 36 48
Combined Total Revenue Loss for all turbines-
Crore
163.29 1036.8
Sl
19
What this can deliver to NTPC
For New Green field projects
NTPC has ambitious plan to have 128000MW installed capacity by 2032 if we
consider current installed based & non-fossile portfolio, you are sure to add @51000
MW and majority to come from supercritical ( 70%)
Unit Size < 250 MW 660 MW & ABOVE