STEAM TURBINE

500 MW

CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)

ERECTION

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 work as a fix 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 works. During
erection all the bearing are supplied to site in aligned and assemble condition in
their individual pedestal from the works. After alignment of the bearing in
their pedestal the seat of the bearing are doweled before dispatch to site.
In case of Thrust and Journal bearing the seat of the bearing neither doweled
from the works 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
1.2.1. After opening the pedestal remove and clean the bearing including
its spherical/ cylindrical seat.
1.2.2. Remove oil guard ring and its duct and keep them in proper place
for their storage at site.

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ERECTION

1.2.3. Handle bearing carefully to avoid any damage to the babbit

and its torus/spherical piece. During storage at site avoid direct
loading of bearing on its torus. A thick rubber seat may be used
during handling of bearing at site on its torus.
1.2.4. Ensure 0.03 feeler tightness on bearing parting plane. In case
of any variation the matter may be referred to designers.
1.2.5. Measure bore dia of the bearing and journal dia at site and ensure
the oil clearances. If any discrepancy is observed , designer may
be referred.
1.2.6. Ensure torus/spherical contact with their seats at site. While
checking the contact the seat may be bolted with their
pedestal. In case variation contact from their specified diagrams
are noticed then following may be carried out at site:

In case of torus to cylindrical seats the line contact are

recommended by designers. If these lines are not straight
and are in angle then the bearing may be rejected straight way
and sent to works for rectification. These line contact may be in a
width of about 20 mm throughout on its seat leaving with area
on both sides. The contact may be wide in Center and then
gradually reducing on sides. In 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. In case if the bottom is
tight to a feeler of 0.03 mm the bearing may be accepted at
site without doing any rectification.

In a reverse case the contact are achieved in center only though

the 0.03 feeler is not going in the side. The bearing may be still
accepted at site. In case if the feeler is going in the bottom or in
sides by 0.03 mm. the bearing are not accepted at site and can be
sent back for the rectification to the works. Similarly if the contact
are intermittent on its seat but in a straight line and no feeler is
going the bearing may be accepted. In case of very wide contact
also the bearing may be sent back for the rectification. While
checking these contact very light color may be put on torus of the
bearing. Before sending back the bearing to the works the matter
may be referred to designers and their concurrence is to be
obtained.
No scrapping/lapping is recommended in these
bearing for improvement of the contact.

In case of spherical to spherical bearing the contacts are called in

the center like a moon shape. In these bearings even full
contact may be accepted. But in case if there are contact on sides

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CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)

ERECTION

and a feeler gap is noticed on center then the bearing may not
be accepted.
In such cases if the gap
is upto 0.03 mm then
the
matching/lapping may be carried out at site. But in case of higher
gap the matter may be referred to designers. In case of reverse
case if the feeler gap of 0.03 is noticed on both sides of the
bearing the bearing may not accepted at site and matter may be
referred to designers.
1.2.7. Before checking the contact between torus and its seat ensure that
the seat is feeler tight to 0.03 mm without tightening of any bolts
with the pedestal. If necessary this may be corrected with
consultation of designers. Similarly ensure contact between torus\
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.
1.2.8. Before checking 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.
1.2.9. The sizes 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 3-4 numbers only even after complete alignment of
machine. A protocol for number of shims may be prepared.
1.2.10.Torus/spherical should not have any radial movement over its
bearing.
This can be seen after opening the torus from the
bearing.
1.2.11. Check jacking oil lines of the bearing and clean them thoroughly.
Ensure jacking oil lines fittings also for their male female threads
etc otherwise this may create the oil leakage through these lines
during operation of the machine. The jacking oil pocket in the
bearing may be checked if necessary they may be corrected at
site as per the drawings.
1.2.12. When ever JOP is not available, use always thick oil during
rotation of shaft over bearing.The type of oil may be used as
servo cylinder 1000 grade of IOC.
1.2.13.After installation of bearing in position the oil clearances may
be checked after few rotation of the shaft. But the final oil
clearances are to be checked after final coupling of the shaft. In
case of variation in side oil clearances no cutting of babbitt metal
is permitted at site. Any variation in clearances may be counter
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CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)

ERECTION

checked by measuring journal / bearing bore dia. Bearing bore dia

is to be measured by assembling and tightening of top & bottom
halves of bearing.
1.2.14.In case of skew side oil clearances, the investigation may be
carried out, if necessary consult manufacturing unit.
1.2.15.Ensure 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 checking with blue color. Ensure
full contact of shaft over the jacking oil pocket also.
1.2.16.Always cover rotor journal with the upper half bearing to avoid
entry of any sand particles etc. in the bearing . During pouring
of oil the upper bearing may be removed and replaced back after
the pouring of oil.
1.2.17.After completing the reaming/honing and final tightening of
coupling bolts the work of bearing side pad, yoke keys and oil
guard fitting may be taken up.
1.2.18.Before starting the side pad and top keys ensure that the bearing
is perfectly level on parting plane. Ensure that the gap for the side
pads are
parallel otherwise
these are to be made by
cutting/scrapping.
1.2.19.After fitting of the bearing cap if the gap for the radial top keys are
in taper a proper correction is to be made here. The bearing cap
may also be repositioned to achieve the parallelity of the key
way. The cap may be re-doweled after repositioning it but no taper
are to be left on these area. If repositioning of cap is not helping
then the cutting may be carried out in bearing cap.
1.2.20.The gap for the top packer of bearing may also be checked. In
case of any taper the same is to be corrected by cutting on
bearing cap. Sometime the size of this packer comes to very
low i.e. even below 5.00 mm. This may be corrected by
matching the cap and size for this packer may be kept around
6.00 mm.
1.2.21.On all these bearing cap key a proper fitting and clearances are to
be maintained during assembly. These key of proper material
are to be only used and no welding deposits are permitted here.
The new key may be made at site by EN-24 material if correct key
are not available at site.
1.2.22.Use of local made shims in bearing may be avoided and shims
supplied from the works with proper cutting of holes are to be
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ERECTION

used. Ensure drawing requirement of maximum adjustment at site

by + 0.3mm in shim size from manufactured condition.
1.2.23.A proper care should be given during fitting of bearing oil guard
ring otherwise it causes the oil leakage 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.
1.2.24.The bearing parting plane bolt are to be tightened to required
torque only no other method of tightening of these bolts may be
used.
1.2.25.Adjustment of shims between spherical/torus and bearing body is
limited to +0.30 mm in up and down and left, right direction. this
margin may be left for emergency work 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. For left and right adjustment the
complete pedestal of HP front and HP rear may be moved with
the help of their radial keys.
The above discussed points were common for Journal bearing
and combined thrust and journal bearing. Now some specific
points are detailed here for the assembly of combined Thrust
and Journal bearing:

Remove all the thrust pads before placement of bearing in

position and store them in a proper place.

Pressure proper fitting of babbitt metal liner in the bearing body

including necessary pinch in the fitting of its liner.

During alignment of rotor along the bearing with respect to the

shaft

by moving

spherical

seat of

the

bearing radially and

axially.

No elongation of holes are to be carried out in spherical sat of

the bearing for the purpose of its alignment.

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CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)

ERECTION

Before deciding axial position of the bearing the axial position of the
rotor is to be determined. If necessary the H.P. rear pedestal as a
whole may be shifted axially 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 thicknesses.

Movement in the thrust pad should be ensured and a difference in

thickness of packers including shims should be with in + 0.10 mm
may be permitted on front and rear pad sizes in exceptional cases.

After ensuring the perfect alignment of the bearing the axial keys
are fitted after assembly of upper half bearing. These axial keys
are to be fitted in perfect parallel slots without any clearances.
The keys are to be fitted in such a way that there is no movement
to the bearing during fitting of these axial keys. Necessary dial
gauges are to be installed on bearing during fitting of these keys.

After completion of axial key works of the bearing the thrust pads
may be fitted in the bearing with a clearance of about 0.10/0.15
mm.

Before fitting of pads in the bearing ensure that there dimension

are made parallel to suit the front and rear slot size of the bearing
(size between thrust collar and bearing body).

Ater fitting of pads in the bearing ensure their free movement

over the bearing.

Install lower half bearing in position along with their pads and put
very small quantity of oil on journal then rotate the rotor and put

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ERECTION

blue color on the thrust collar of the rotor on both front and rear
side.

Install upper half bearing along with all pads and fix their axial keys.

Rotate the rotor and move + direction axially with the help of
wooden planks. Remove both halves of the bearing and see the
blue contact on thrust pads. If necessary some cutting may be
carried out

on

the pads to achieve

the

color contact.

This

exercise may be repeated few times to achieve the blue contact

Ensure a float of 0.30 + 0.10mm during color matching of the

thrust pads. If necessary the minor adjustment of shims may be
carried out in the bearing pads.

Before installation of thrust bearing along

with thrust pads in

position the both halves may be bolted out side and their pads
may be checked 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.

During overhauling of the unit

the bearing contact are to be

rechecked and need correction. In case of torus to cylindrical

type of bearing if

the contact are not satisfactory then the

bearing and its seat may be remachined at works.

In spherical

to spherical bearing the variation in contact if noticed

be

corrected

can

by matching/lapping at site. Sometimes the

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

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CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)

ERECTION

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STEAM TURBINE
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CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)

ERECTION

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STEAM TURBINE
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CRITICAL ACTIVITIES
(ASSEMBLY OF BRG. AT SITE)

ERECTION

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STEAM TURBINE
500 MW

CRITICAL ACTIVITIES
(BUMP CHECK)

ERECTION

2.

BUMP TEST
The axial clearance check

is determined after

radial clearance

measurement has been completed.

In this case the shaft is shifted in the + and - directions from its
operating position and the dimensions with the shaft in limit position are
measured using a depth gauge.

Note: Enter the measured values ( actual dimensions ) on the record sheet
and compare them with the specified dimensions.

If the deviations from the specified dimensions is greater then the

permitted tolerances, the manufacturer must be consulted.

Note : Based on the readings of bump check, axial position of the shaft wrt
casing is not to be altered.

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Rev 00,
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CRITICAL ACTIVITIES
(ROLL CHECK)

ERECTION

3.

ROLL CHECK
3.1.

GENERAL DESCRIPTION

In KWU machine the minimum radial clearances HP, IP and LP 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. Such 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 check method but equal importance should also be given to the centering of
HP and IP 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.

3.2. PROCEDURE
ROLL CHECK OF HP AND IP CASING
3.2.1. Alignment and coupling of HP-IP and LP rotors are to be
completed before starting the rolling test of the casing in normal
case but this can be done without coupling of LP rotor also.

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3.2.2. Centering of the casing on HP front, HP rear IP front and IP rear

spigot are also to be completed before starting of the rolling test.
These readings can be compared as per the factory protocol
also. Fix temporary radial and axial keys of the casing before
rolling test of casing. During dialing on spigot a proper care
should be taken that the dials are properly mounted over the
fixture and the fixture 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.
3.2.3. All the four jacking screw of HP and IP casing are to installed
along with dial gauges for monitoring of up and down, and left
and right movement of the casing.
3.2.4. One number hydraulic jack on each corner of the casing along
with a spanner on each corner for jacking screw are also to be
made available.
3.2.5. During erection of machine the turbine rotor are generally rotated
by hand with the help of periphery holes on coupling. Two
pipes of about 1250 mm long along with a pin to suit the dia of
periphery may be used for rotating the rotor shaft. The initial jerk
to the rotor is given by the help of crane and it is further rotated
by these pipes through periphery holes of the coupling. During
overhauling generally the jacking oil system is available and the
rotation of rotors are achieved with the hand barring of the
machine.
3.2.6. Before starting the rolling check it should be ensured that the rotor
shaft is absolutely free on manual rotation/hand barring as
the case may be. During manual rotation two persons are to be
employed for this work and during hand barring only one person
is enough.
3.2.7. Always use thick oil for rotation of rotor over bearing in absence of
jacking oil system. The type oil may be servo cylinder 1000 grade
(IOC) oil.
3.2.8. During the rolling test the temporary casing packers are to be
fitted with about 1.00 mm shims.
3.2.9. During the rolling test of any one of the casing the same is lifted
first on all four corners in a step of 0.05 mm with the help of
hydraulic
jack and jacking screw. The rotor is also rotated
manually side by side with the lifting of casing. The rotation of
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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 0.05mm and rotor is
rotated again if it is completely free. In case the rotor is still tight on
its manual rotation the casing is further lowered by 0.05 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

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 0.05 mm and
freeness of rotor is ensured. In case it is still tight the casing is
further lowered by 0.05 mm. On front end and the freeness of
rotor is achieved. Now 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
jacks and jacking screws to its original zero-zero position.
Repeat 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. Before starting the rolling test in

downward direction of the casing remove about 1.00 mm shims

from each packer

of the

casing,

but

kept

the

casing

on

hydraulic jacks and jacking screws on its original position. The

casing is again brought back to

Bharat Heavy Electricals Limited

Rev 00, 7-98

its

original position by

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installation of the shims back to the packers of the casing after

recording the top clearances of the casing.
After recording the up and down rolling test values the radial
keys of the casing are removed and again rolling test for left
and right direction are done similar to up and down. During this
process the radial dial on the casing are also installed. After
this check the casing is brought back to its zero position in radial
direction also.
After completing the rolling test readings of one of the HP/IP
casing

in up/downand

left/right

direction

the clearances are

readjusted as required at site in radial direction by moving the

casing with the help of temporary radial key or shims on the casing
packers. The casing is then locked on four corners and
dial readings of spigot

final

are recorded on front and rear end.

Immediately after this the final radial key of the casing are fixed
and the locked of the casing are released for fitting of the final
casing packers. The final spigot dial reading are repeated and
confirmed with the earlier readings.
3.2.10.After doing the full rolling test and fixing of a final radial keys
and packers of one of the casing the rolling test of another casing
is done including the fitting of final keys and packers.
3.2.11.Necessary offset in the radial clear-ance is also kept before
fitting of final packers of the casing toward the lift of the shaft
during operation of the unit.
3.2.12.No inlet and outlet pipes are to be welded with the casing till
completion of rolling test and installation of final keys and packer
of the casing.

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3.2.13.Radial clearance of the casing are to be ensured with reference to

the factory supplied protocol also.
3.2.14.After fitting of final keys and packers of the casing the final
spigot dial values of HP front, HP rear, IP front and IP rear
casing are to be recorded for future reference in the protocol.
3.2.15.The horn drop readings are also to be checked after the fitting of
final packer of the casing.
3.2.16.In case of IP casing the roll test readings are to be taken with
the IP front end rear shaft scales. The spigot dial readings are also
to be taken over the spigot of shaft seales.
3.2.17.During rolling test of the HP and IP casing if the rotor is rotated
over the jacking oil then the adjustment of readings are to
adjusted for the lift of the rotor also.
3.2.18.Four numbers 1.00 mm undersize packers for HP & IP casing
may be made during erection and supplied to customers as T&P
items for further roll test during overhauling of the unit. If any
taper is left on final packers of the casing then these four packers
may be made to similar taper also.

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3.3.

ROLLING TEST OF L.P. INNER CASING

3.3.1. The rolling test of L.P. inner casing is done similar to the HP or IP
casing but both side joints of L.P. inlet bellows are kept free or
bellow itself are not positioned at all, till completion of rolling test.
But during overhauling the rolling test is done with already welded
bellows.
3.3.2. Rolling test of L.P. inner casing is done after the neck welding of
condenser andstiffener pipes inside the condenser. This include
the welding of stiffener pipes of L.P. casing and gusset plates
also.
3.3.3. After rolling test of the casing the final radial keys of the Gusset
block and casing packers on all four corners are installed.
3.3.4. Necessary offset in the radial clearances of the casing is also
kept before fitting of final L.,P. inner casing packers.
3.3.5. Radial clearances of the casing are to be ensured to the design
values. In case of any variation the matter may be referred to the
designers.
3.3.6. If the rotor is rotated on jacking oil then the rolling test readings
are to be adjuted for the lift of the rotor also.

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CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)

ERECTION

4.

CATENARY AND ALIGNMENTS

4.1.

General Description

The catenary of the machine is very important for a turbine and Generator
assembly to achieve proper alignment of various rotors and loading on their
bearing. Any

deviation may

lead to various operational

machine like high shaft vibration,

problem

in the

high bearing vibration, high babbitt metal

temperature of the bearing etc. To avoid these problems it is necessary to

maintain

the catenary

of the machine during erection

and subsequent

realignment/overhaul of the unit. Many 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. In order to avoid such
derivation a need is felt to devise a procedure which shall ensure rotors
alignment alongwith proper catenary of the machine.

During 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.
In each overhaul of the unit the catenary of the machine is to be corrected.
The L.P. front and L.P. rear pedestal are directly grouted

here without any

separate base plate. As such any correction on lifting or lowering. These

pedestals are not very convenient

so if necessary the rotor may be lifted or

lowered with respect to pedestal seal bore and required catenary may be
achieved. In extreme cases these pedestals may be

even regrouted during

major overhauls of the unit to correct the catenary of the machine.

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4.2.

CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)

Procedure

4.2.1. Install a bench mark plate near L.P. rear pedestal as height of
the machine center line with the consultation of civil Engrs at site.
A plate of 200 m.m x 300 m.m size with 20 m.m thickness
machined/ground on top side may be welded over a I Beam 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.
4.2.2. Record half bore error of all the four pedestals and confirm the
readings with the factory records also. The half bore error may be
checked 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.
4.2.3. During alignment of pedestal at the time of grouting with
conbextra cement set the height of the pedestals as per required
catenary of the machine considering +value for the half bore error
of the pedestals. While setting the height of the pedestals it should
be kept in mind that the height for the center of the pedestal bore
are to be kept as per the catenary of the machine not the
parting plane of the pedestal.
4.2.4. For better results four water level jar connected to each other
with a polythene pipe may be installed on each pedestal. The
D.M., water may be used here and leakage through polythene
tubes should be avoided fully while making the connections. These
jars may be fabricated at site by about 125 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 kept as about 175
mm. A depth micrometer installed and clamped over a magnetic
base is also required 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 0-10mm dial gauge may be used.
4.2.5. .During measurement of water level in the jar the micrometer is to
be kept approximately 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 taken
during this measurement i.e. there should not be any air bubble in
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Rev 00, 7-98

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ERECTION

CRITICAL ACTIVITIES
(CATENARY AND ALIGNMENTS)

the polythene pipe and the

stationary.

polythene pipe should be kept as

4.2.6. While finalizing the catenary of the machine these measurements

are to be repeated 3-4 times in a day at different intervals to avoid
any possibility of the error.
4.2.7. The height of the L.P. rear pedestal is the reference point for
setting the height of all other pedestal and L.P. base plates. The
L.P. rear pedestal height is to be first made with the benchmark
plate as per the center line of the machine with the help of water
level jar.
4.2.8. The benchmark plate is to be preserved for all future references.
4.2.9. The catenary is to be counter checked after grouting all the
pedestals as well as after final alignment of the rotors. The final
value of the catenary may be worked out as center of the shaft on
each pedestal bore after taking 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.
4.2.10.After ensuring the required catenary of the machine the coupling
alignments are to be made as parallel coupling.
4.2.11.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 checking of catenary
may also be used i.e. optical measurement method or a method
by which direct journal heights are taken on each bearing in place
of pedestal height.
4.2.12.For measurements of direct journal height a special fixture is to
be fabricated and necessary information about it can be separately
given by PS-TS if such necessity arises.

5.

HORN DROP TEST

5.1.

General description

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CRITICAL ACTIVITIES
(HORN DROP TEST)

ERECTION

By 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 extraction pipe lines etc. The horn
drop readings are very important in HP & IP casing. First the proper horn drop
readings are made without connection of any pipe lines and then the reading
are taken after welding of all pipe lines on HP & IP casing. As such the
influence of these major pipe lines are notices on each corner of HP/IP
casing by comparing the horn drop

test readings. The horn drop test will

indicate the quality of work during assembly/welding of pipe lines with the HP &
IP casing.

This is a very important check and may cause serious problem in operation of
the machine like high vibration in the machine failure of barring gear in hot/cold
machine, obstruction during expansion of machine etc. In 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.

In Russian design machine the

value of direct dynoxmetre

loadings are recorded in place of this horn drop test.

Bharat Heavy Electricals Limited

Rev 00,
7-98

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CRITICAL ACTIVITIES
(HORN DROP TEST)

ERECTION

5.1.1. Procedure
5.1.2. After placement of HP and IP casing on four temporary packers
ensure that the each corner of the casing is loaded on temporary
packer and if necessary the shims may be given on packer for
loading of the casing. The load of shaft is also taken on transport
device during this stage.
5.1.3. After transferring the load of the rotor on bearing and ensuring the
casing centering with respect to shaft the horn drop check may be
carried out.
5.1.4. Before taking 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 0. 20 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.
5.1.5. No adjustment on packer of the HP front and HP rear pedestals
are to be carried out after taking the horn drop test of the casing
In case if any adjustment is carried out on these pedestal
packers then horn drop test are to be repeated again.
5.1.6. No piping may be connected to HP & IP casing till initial horn drop
readings are over. The piping work should not be postponed for
want of horn drop the only thing the last joint with HP/IP casing
may be left free till completion of horn drop check.
5.1.7. While recording the horn drop readings the casing must be
absolutely free and even the radial and axial key 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 axial and
radial keys are fitted in the casing and even they carry some
shims also. Before making the casings free on axial and radial
key portion the dial gauges are to be installed to monitor the
movement of the casing on radial and axial direction.
Immediately after the completion of the horn drop test these
keys/shims may be installed back and centering of casing may
be rechecked before further works.
5.1.8. In HP casing the initial horn drop test may be done even after
fitting of breach nut assembly and HP exhaust elbow of both sides.

Bharat Heavy Electricals Limited

Rev 00,
7-98

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CRITICAL ACTIVITIES
(HORN DROP TEST)

ERECTION

5.1.9. In IP casing the initial horn drop test may also be done after fitting
of IP inlet pipe lower half assembly but this pipe of upper half
casing should not be fitted till completion of the horn drop test.
5.1.10.All the four Jacking screw and hydraulic jack 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.
5.1.11.After initial centering of the casing the each corner packer may
be fitted with a shim of about 1 mm. for further adjustment during
the horn drop test.
5.1.12.During the horn drop test the individual packer of the casing
is removed and the load of that corner is supported over the
jacking screw of the casing. Now gradually the jacking screw is
also relieved with the help of hydraulic jack on that corner and
drop reading is recorded. This is repeated for each corner of the
casing. In case of variation in left and right side reading the
drop is adjusted by + adjustment of shims from left to right side
or vise-versa. No subtraction / addition in shim sizes from outside
is done here and only the shims are adjusted from left to right or
vise versa till equal loading are achieved in left/right side of
individual casing. The sizes of these casing packers are recorded
after completion of horn drop to avoid any confusion at a later
date while fitting the final packers.
5.1.13.While recording the horn drop readings the drop on each
individual corner may be controlled with the help of Jacking
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.
5.1.14.During the initial horn drop the best reading within 0.05/0.06
may be achieved by fine adjustment of the packer shims. The
comparison in horn drop value should always be made in left and
right side only of an individual casing.
5.1.15.In case of HP casing the drop on rear end is so high that unless
the casing is locked on diagonally opposite end the horn drop
check is not possible. Therefore while recording drop on HP rear
end the front end of the casing diagonally opposite to it should
be locked with casing clamp. The pedestal is also required to be
locked on all four side with its sole plate with the help of the
clamps. In case of IP casing no locking of any corner of the casing
is necessary during the horn drop test.
Bharat Heavy Electricals Limited
T1-08-0806G
Rev 00,
7-98
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CRITICAL ACTIVITIES
(HORN DROP TEST)

ERECTION

5.1.16.The final packers on HP & Ip 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 fixing of final
packers also. If necessary a fine adjustment may be carried out at
this stage to achieve correct value of the horn drop reading.
5.1.17.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 taken along with its radial
and axial keys of the casing.
5.1.18.During this stage exactly this can not be defined that how much
variation is permitted on these values of horn drop readings., But
this variation will indicate the influence of the piping load on
the HP/IP 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. But 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 making again a free
joint with the casing.
5.1.19.During variation of horn drop reading no correction is to be
made on casing packers by adjustment of shims etc. The
variation at this stage is caused due to the piping pull/push only
so if any correction is required 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. Even some time it is necessary to cut the
individual or more piping joint for correction of horn drop readings.
5.1.20.The variation in horn drop reading of left and right side of a casing
may be permitted upto a difference of 50%.
5.1.21.The horn drop readings are not taken for L.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.

Bharat Heavy Electricals Limited

Rev 00,
7-98

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CRITICAL ACTIVITIES
(SWING CHECK)

ERECTION

6.

SWING CHECK
6.1.

GENERAL DESCRIPTION

The swing

check 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 check value

may cause higher shaft vibration, higher bearing

shell temperature etc. The value of swing check depends on axial runout of
coupling faces, the diameter of the coupling and the length of the rotor. During
the machining of

rotors in the works some tolerances are permitted by

Designer's on the coupling faces of the rotor resulting to some swing check
values. The maximum swing
above tolerance

check values permitted caused due to the

for different diameter and length of the rotor

can be

worked out from the enclosed graph. However it is recommended to keep the
minimum swing check values for better results during operation of the machine.

In a multi rotor Turbine-Generator system it is essential to measure the swing

check value in both extreme end and where the weight of the rotors are light.
For example 200/210 M.W. KWU machine with Russian

Generator and

static excitation system the swing check values are measured on HP rotor front
end only. In 500 M.W. machine the swing check values are measured in H.P.
front end and on exciter rear end. After having general experience of number of
200 MW & 500 MW units, a necessity is felt to measure swing check value on
IP rotor front end also for better results during operation of the units. This can
be done initially during

erection with temporary

coupling before reaming/honing of coupling. Any

Bharat Heavy Electricals Limited
Rev 00,
7-98

coupling bolts on LP-IP

variation in swing

check

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CRITICAL ACTIVITIES
(SWING CHECK)

ERECTION

values may be corrected without any hesitation during erection of machine.

Any compromise at

erection

stage may cause serious problem

during

operation of the unit and any correction becomes much more tedious a later
stage. The correction

may

coupling position

by correcting

or

be

carried

out
the

either

by interchanging

coupling

faces

the
by

scrapping/cutting in consultation of Designers.

6.2.

PROCEDURE

6.2.1. Before placement of Module/Rotor in position the coupling faces

of all the rotors are to be measured for concavity/convexity of
their coupling faces. This can be checked with the help of a thin
rectangular light weight straight edge. No convexity is permitted on
these coupling faces however a concavity of about 0.03/0.04 mm is
permitted. In case of any variation the matter may be referred
to manufacturing units.
6.2.2. After placement of individual Module/Rotor the coupling faces
are to be measured for axial runout before taking up alignment
of various rotors. The HP rotor rear coupling face can be
measured after placing it on both of its bearing. The IP rotor
faces are to be measured after placing IP rear end on bearing
and front end on lifting tackle. Similarly L.P. rotor, may be placed
on bearing on its rear end and front end supported on lifting
tackle. Any variation on axial runout on coupling faces for more
then the 0.02 mm. may be referred to Designer's before taking up
further works.
6.2.3. After completing final alignment of various rotor they are to
be coupled with temporary bolts, considering their axial
runout/geometric form of the coupling faces.

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Rev 00,
7-98

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CRITICAL ACTIVITIES
(SWING CHECK)

ERECTION

6.2.4. During 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.
6.2.5. During coupling on temporary bolts the uniform tightening on all the
four temporary bolts are to be ensured otherwise it will disturb
the swing check value of the rotor.
6.2.6. First IP-LP coupling is to be made with temporary bolts and swing
check on IP rotor front end is recorded. After this only HP-IP rotor
is to be coupled with temporary bolts and the swing check value
on HP front rotor is recorded.
6.2.7. During swing check of IP rotor its front end is to be supported
on lifting tackle without making any connection between HP-IP
rotor.
6.2.8. While recording swing check of HP rotor the front end of the rotor
is to be supported on lifting tackle.
6.2.9. During swing check the lifting tackle are to be fitted properly. The
tie rod of lifting tackle should be ensured for correct fitting of its
spherical bearing and Molykote should be applied on these
spherical bearing for their free movement. These spherical
bearing should not obstruct the movement of shaft radially during
checking of its swing check value.
6.2.10.After taking the load of the rotor on lifting tackle ensure that the
rotor is not disturb radially due to fitting of lifting tackle.
6.2.11.During checking of swing check measure radial movement of rotor
on parting plane and rotate the rotor either on jacking oil with hand
barring or with the help of E.O.T crane with thick oil on bearings.
Avoid jerk during rotation of rotor while recording the swing check
values.
6.2.12.After ensuring the swing check values as per the graph with on
temporary coupling bolts, the HP-IP and LP-IP coupling may be
cleared for reaming / honing of the coupling holes. Any variation
need correction of the coupling before reaming/honing of the holes.
6.2.13.The final swing check value of HP front rotor is to be recorded
after fitting/ elongation of all the coupling bolts of HP-IP & LP-IP
rotors. Any variation in readings may be referred to the Designer's.
For improvement of the swing check values, the indifferent
tightening and non-sequential
Bharat Heavy Electricals Limited
Rev 00,
7-98

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CRITICAL ACTIVITIES
(SWING CHECK)

ERECTION

6.2.14.During checking of swing check 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.
6.2.15.Similar method is to be adopted while checking the swing check
value of the exciter except the rotor is hanged on the suitable size
of sling in place of the lifting tackle.
6.2.16.While recording the swing check initially with temporary bolts
for HP & IP rotor, the fitting of eight number temporary bolts are
preferred in place of four bolts on the coupling.

Bharat Heavy Electricals Limited

Rev 00,
7-98

T1-08-0806G
Page No. 28of 40

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500 MW

CRITICAL ACTIVITIES
(SWING CHECK)

ERECTION

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Rev 00,
7-98

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CRITICAL ACTIVITIES
(COUPLINGS & ALIGNMENTS
OF ROTORS)

ERECTION

7.

COUPLINGS & ALIGNMENTS OF ROTORS

7.1.

GENERAL DESCRIPTION

The coupling on turbine shaft are generally rigid coupling but in case of L.P.
rotor sometime the coupling head are shrunk 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 required during manufacturing of these rotor shaft
at works. The axial runout on the coupling face may not exceed 0.02 mm.
and an additional check is also made at works/site to ensure that the geometry
of the entire coupling surface does not deviate by more then the 0.02 mm.
except the concavity on the coupling face which is permitted upto 0.03/0.04
mm.
The radial and axial 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 checks determines both the radial
and axial position of the two adjacent coupling flanges relative to one another.
The radial

measurement

are

performed

on

the circumference of the

couplings and the axial measurement are performed on outer most diameter
of the coupling. During coupling of the two shafts it should be ensured that the
no stresses are exerted 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 axially. Here equal importance is given to the radial & axial

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Rev 00,
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ERECTION

alignment

CRITICAL ACTIVITIES
(COUPLINGS & ALIGNMENTS
OF ROTORS)

of stationary parts to avoid any rubbing

during operation of the

machine due to expansion of stationary and rotary parts.

During the alignment of two coupling both are to
and

by

be turned in same direction

the same amount when the measurement are taken to avoid

the

influence of the axial & radial runout present in the shaft caused due to the
machining.

7.2.

PROCEDURE

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Rev 00,
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ERECTION

CRITICAL ACTIVITIES
(COUPLINGS & ALIGNMENTS
OF ROTORS)

7.2.1. Before placement of module/rotor in position check and record the

coupling hole and journal dia of the shaft.
7.2.2. Check
coupling faces
for the concavity/convexity with
the help of a thin rectangular straight edge before placement of
module/rotor in position.
7.2.3. Check spigot and recess of the coupling and ensure their fitting
before placement in position.
7.2.4. Place the module/rotor in position and check the radial runout of
journal and axial runout of the coupling faces independently of
each shaft. During checking of radial and axial runout of the shaft
place H.P. rotor on both of its bearing and IP/LP rotor one end
on its bearing and another end on the lifting tackle. The radial
and axial face runout on the shaft should be within 0.02 mm
accuracy. Any variation may not be permitted here and matter may
be referred to the designer's.
7.2.5. The HP,IP & LP rotor are aligned together and then their couplings
are made. After fully completion of HP/IP & IP/LP coupling with
tightening of their final bolts the complete shaft is cleared for
Generator rotor alignment.
7.2.6. During initial alignment of HP/IP & IP/LP rotor the radial checks
are generally done with the help of depth micrometer and axial
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 axial gap values.
7.2.7. During final alignment only the axial gap values are checked at
90o on four places by rotating both the rotor together and
average of these four reading are taken. The radial alignment
reading along with axial gaps are necessary wherever the
effective spigot are not existing in two couplings i.e. in case of LP Gen coupling the radial dial reading are also taken.
7.2.8. Avoid rotation of two shaft in their spigot. If necessary these may
be rotated after taking out from their spigot.
7.2.9. During alignment of shafts the adjustment of shims in bearing
torus may be fully avoided. The margin of + 0.30 mm. in height &
left/right direction may be kept for emergency works only. Any
adjustment during erection and normal overhauling may be done
by adjusting shims between spherical/cylindrical seat and
pedestal base only. For left and right adjustment the complete
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Rev 00,
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ERECTION

CRITICAL ACTIVITIES
(COUPLINGS & ALIGNMENTS
OF ROTORS)

H.P. front and HP rear pedestal may be moved with the help of
their radial keys.
7.2.10.The final packers 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. But during overhauling of
the machine the adjustment may be carried out in these packers
for correction of catenary of the machine.
7.2.11.During alignment of rotor make HP/IP and IP/LP coupling gap
parallel. After completion of final alignment no adjustment of
packers and keys etc are permitted on pedestals and bearing the
final alignment of HP/IP & IP/LP rotors should be checked after
fitting of all the final keys and packers of the pedestals.
7.2.12.After alignment couple the HP-IP & IP-LP rotors on temporary
bolts. Record coupled runout of the rotor and ensure that the
coupled runout is not more then 0.03 mm. in any where in the
journal as well as in coupling area. Before coupling of rotor on
temporary bolts record their spigot clearances by actually moving
the rotor radially.
7.2.13.During erection IP-LP swing check on IP front and HP-IP swing
check on HP front are to be recorded on temporary bolts. These
reading are to be ensured within the design limit.
7.2.14.Before alignment/coupling position the two shaft adjustment to
each other depending upon the higher and lower point of the shaft
with respect to their axial face measurement values.
7.2.15.The HP-IP & IP-IP coupling may be cleared for reaming/honing
after ensuring the runout and swing check values of the rotors.
In case of variation the cause of the error may be identified and
corrected before further work of reaming and honing of the
coupling.
7.2.16.During 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.
7.2.17.As for as possible ream/hone all the coupling bolts holes to
same size. In exceptional cases only the variation in hole
sizes are permitted. Each hole during honing should be checked
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Rev 00,
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CRITICAL ACTIVITIES
(COUPLINGS & ALIGNMENTS
OF ROTORS)

for bananas shape with the help of a parallel ground straight pin
of 0.02/0.03 undersize. No banana shape is permitted in any of
the hole. The hole should be made to 0.005 mm accuracy.
7.2.18.All the coupling bolts are to be machined and ground by
0.02/0.03 mm undersize then the hole dia. These bolts are to
be fitted with thumb pressure only and no additional force is
recommended while fitting these bolts.
7.2.19.A very thin layer of molykote may be applied on all the
coupling bolts during their fitting. The molykote should not be
applied on seating face of the coupling bolts. This may cause
in breaking of their locking pin during elongation of coupling
bolts.
7.2.20.All the coupling bolts are to be balanced before finally
fitting/tightening in position. These are to be balanced within an
accuracy of 5 gms each along with their nuts. In case all these
bolts are of equal size then their weight must be equal. In
exceptional cases the 180o opposite bolts may be made of equal
weight.
7.2.21.During tightening of coupling at any stage first tighten four bolts
on 90o location. Always tighten bolts in proper sequence
with 180o opposite bolts. These bolts are to be elongated to the
value given over drgs.
7.2.22.During tightening of coupling the radial runout on journal and
coupling may be checked at various stages during tightening of
bolts. The final coupled runout should not be more then 0.03 mm.
on coupling and journal of the shaft.
7.2.23.After final tightening of LP-IP and HP-IP coupling the swing
check value on HP front rotor is to be rechecked. In case of
variation in value a proper correction is
to be made with
consultation of designer's.
The indifferent
or unsequential
tightening for achieving the swing check value or coupled runout
value may be fully avoided. this may cause unnecessary stresses
on the coupling.
7.2.24.After completing the coupling work the casing radial and axial
alignment may be done.

Bharat Heavy Electricals Limited

Rev 00,
7-98

T1-08-0807G
Page No. 34of 40

STEAM TURBINE
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ERECTION

CRITICAL ACTIVITIES
(Welding of steam inlet and exhaust
pipe lines with HP and IP casing)

Welding of steam inlet and exhaust pipe lines with HP

and IP casing
In 210 MW machine the HP Turbine is supplied with two inlet and two exhaust
flanges for connection of the pipe line.but in case of 500/250 MW HP Turbine
the casing is supplied with four inlet flanges also. As such in 200 MW machines,
only two ESV control valves are used in the system. Whereas in 500/250 MW
machines , It may be either two ESV oontrol valves or four ESV control valves to
cope with the design of the casing.
Similarly in 210 MW machines, the I.P. casing is supplied with two inlet flanges
and eight number exhaust branches or either two exhaust branches only along
with two inlet flanges. These eight number exhaust branches are distributed four
on each side of the casing and each four branches are joined together with one
common pipe while connected to L.P. casing. The 500 MW I.P. casing is similar
to the 210 MW I.P. casing but some time these are supplied with four numbers
of I.V. control valves also. The inlet lines from each two control valves are joined
together and make one connection with the I.P. casing in bottom. As such in
210 MW machines, only two I.V. control valves are used but in case of 500 MW
machines, there can be either two I.V. control valves or four I.V. control valves.
After completion of the rolling test the installation of final keys and packers of the
H.P. and I.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. Similarly the Hot Reheat lines between
two Hot Reheat strainer to the control valves and from control valves to the I.P.
casing also need equal 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 Erection Engineer
Bharat Heavy Electricals Limited
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Rev 00,
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CRITICAL ACTIVITIES
(Welding of steam inlet and exhaust
pipe lines with HP and IP casing)

in erection / welding of the pipelines at site along with the Piping Engineers. The
piping connection between I.P. casing to L.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 the problems are not
faced during operation of the machine. However if proper care is not taken here
then that may cause the unnecessary loading on the various bellows of the
piping and reduction in their life. In case, if proper care is not taken during
erection / welding of MS inlet, CRH & HRH connections with HP & IP casing, a
load will be transfer from the pipe line to the casing. Which may cause vibration
in the machine, obstruction in expansion 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.

8.

PROCEDURE
8.1.

The following points are to be taken care while welding MS, CRH, HRH
pipelines with HP & IP casing and control valves / strainers.
8.1.1. The HP & IP casings are to be cleared in all respects after fitting of
final packers and axial / radial keys of the casing.
8.1.2. The ESV & IV valves are to be cleared after fitting of their
servomotors and then levelling including the correct elevation etc.
8.1.3. The equivalent 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 back by lifting
the valve with the help of hangers. The control valve hanger reading
should remain same as before and after installation of equivalent
insulation weight on the valve. After this all the three hangers of
each valve are to be locked to avoid any movement of the valve in
upward direction, in case the equivalent insulation weight is
removed or any of the servomotor is removed. Before starting of
any welding with the control valve the valves are to be locked for
their movement.
8.1.4. Erection and welding of MS line upto MS strainer and HRH strainer
are to be completed first including either their insulation or

Bharat Heavy Electricals Limited

Rev 00,
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STEAM TURBINE
250 MW
ERECTION

CRITICAL ACTIVITIES
(Welding of steam inlet and exhaust
pipe lines with HP and IP casing)

equivalent weight is to be given for their insulation weight in the

lines. These lines should be in perfect floating condition on their
hangers before taking up the further work of MS & HRH lines upto
the ESV & IV control valves.
8.1.5. Install MS & HRH lines between strainer and control valves and
weld all the inbetween joins of the pipelines except 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 taking their load on hangers. The
freeness of joints are to be ensured after giving the equivalent
insulation weight of the lines.
8.1.6. Weld MS & HRH lines with the strainers and again ensure the
freeness / paralalllity of MS & HRH lines with the ESV and IV
control valves. Any minor variation may be readjusted on hangers
to obtain the freeness of the joints with the control valve.
8.1.7. Install the MS and HRH lines between control valves and HP /IP
casing . Now all the in between joints may be keeping 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
equivalent insulation weights are also to be added during erection
of these pipe lines before welding the end joints.
8.1.8. After ensuring the freeness and parallelity of the end joints
between ESV control valve and HP casing , the same may be
welded together. But the stress relieving of all the in -between joints
of the lines are to be completed before taking up work of the above
last two end joints . Similar proceedure may be followed for the
lines between I V valves and IP casing also.
8.1.9. Weld left and right MS and HRH joints togethers with the HP and
IP 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.
8.1.10. The CRH 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 MS lines but before weling of these line
the in- between joints are to be completed first . The equvalent
insulation weight is also to be given on these line while checking the
freeness of end joints with the HP casing.
Bharat Heavy Electricals Limited
Rev 00,
7-98

T1-17-0808G
Page No. 37of 40

STEAM TURBINE
250 MW
ERECTION

CRITICAL ACTIVITIES
(Welding of steam inlet and exhaust
pipe lines with HP and IP casing)

8.1.11.The horn drop readings are to be recorded for both HP and IP

casing after copletion of the job including insulation of pipe lines
and control valve etc.

8.2. SPECIAL CARE

8.2.1. If possible keep the insulation weight and servomotors on ESV and
I V control valves during erection /welding of these MS & HRH
lines from strainers to the valve and casing . If the above condition
are fulfilled then there no need of any locking of the valves during
the welding of any pipe lines.
8.2.2. 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 : After complete leveling of ESV and IV control valves with their
servomotors
After putting the equivalent insulation weight on the control
valves.
After readjustements of control valve height equivalent to
insulation weight.
After connection of MS &HRH lines with the strainers .
After connection of MS & HRH lines with the HP & IP casing .
After complete insulation of control valve and pipings.

Bharat Heavy Electricals Limited

Rev 00,
7-98

T1-17-0808G
Page No. 38of 40

STEAM TURBINE
250 MW
ERECTION

CRITICAL ACTIVITIES
(Welding of steam inlet and exhaust
pipe lines with HP and IP casing)

8.2.3. Ensure proper clraning of MS and HRH lines between controls

valve and casing as these lines are not covered in steam blowing
operation . Proper care is to be taken during erection of these lines
to avoid entry of foreign material.
8.2.4. The steam blowing of the MS and HRH pipe line are to be carried
out after fully completing the erection /welding of lines from control
valve to the HP and IP casing .
8.2.5. All the four corners of the casing may be locked with the casing
clamp during welding of piping joints to avoid movement of casing
radially.
8.2.6. The load of the upper half HRH pipe upto the flange supplied by
turbine supplier is taken by the IP casing and by the piping
hangers. This may be taken care while erecting the HRH lines.

Bharat Heavy Electricals Limited

Rev 00,
7-98

T1-17-0808G
Page No. 39of 40