foram

GUJARAT TECHNOLOGICAL
UNIVERSITY

SIR BHAVSINHJI POLYTECHNIC INSTITUTE
BHAVNAGAR

DEPARTMENT OF FABRICATION TECHNOLOGY

L&T MHI TURBINE GENERATORS

PREPARED BY:
1. MILAN J. VISANI (096490355031)
2.CHIRAG P. GOHIL (096490355057)
3. BHUPENDRA SOLANKI (096490355201)
4. CHHATRAPAL RANA (096490355038)


MAJOR REPORT ON
GENERATOR STATOR FRAME

PROJECT NAME: MAHAGENCO-3.
PART NAME: STATOR FRAME.
DROWING NO: A11M430
STAGE FOR PRODUCTION: FABRICATION
MANUFACTURE: L&T HAZIRA, SURAT
MATERIAL: SS 400 JIS
IS 2062 gr A/B


Introduction
To
Steam Turbine


INDEX
•Steam Turbine Basics
• Main component/assemblies/ systems of steam turbine
•Major Sources of Producing Electricity
• Principles of Electricity generation
•Working principal of steam turbine
•Supercritical technology
•Turbine by-pass system
•Major Components used In Turbine
•Shop weld plan
•Test plan
•Quality control plan
•Bill of material
•Stator frame model fabrication sequence procedure
•Box plot plan of generator stator frame
•Process planning sheet
•Some specific terms used in WPS
•WPS
•Functions of generator stator frame


STEAM TURBINE

LP TURBINE

GENERATOR

HIP
TURBINE


STEAM TURBINE
HP PEDESTAL
CROSS OVER
PIPE

RSV&ICV
(Reheat Stop Valve)
(Interceptor Valve)

MSV&GV
(Main Stop Valve)
(Governing Valve)


HIP TURBINE
HIP OUTER CASING HIP ROTOR
(UPPER)

HIP OUTER CASING
(LOWER)


HIP TURBINE

GO TO LP TURBINE

MAIN STEAM INLET
REHEAT STEAM INLET

Generator Stator Assembly


Electricity is the
key ingredient for the
development of a nation


Hydro Power Plant Thermal Power Plant

Prime mover is Hydro Turbine
Prime mover is Steam Turbine
Rotated by energy of flowing
Rotated by steam produced in
Water supplied from Dam
boiler by burning fossil fuels
/ reservoir


Nuclear Power Station Gas based Power Station

Prime-mover is Steam Turbine rotated Prime- mover is Gas Turbine run by
by steam produced in Steam Generator air gas mixture ignited in combustion
by Nuclear fission in the reactor. chamber

World Power generation scenario

Thermal Power Plant are most popular way for producing
electricity on large scale and will remain major source of
power generation in foreseeable future due to relatively

•Low capital cost
•Shorter gestation time
•Easy availability of fuel
•Competitive generating cost
•Reasonable high level of operating
availability


Power generation scenario in India

11
3
Thermal
Hydro
Nuclear
27 58 Gas
.

Major share in installed capacity and planned in future is thermal


Thermal Power Plant


Working Principal Of Steam Turbine

Nozzle Plate

Force
‘F’

F

CHANGE IN MOMENTUM = m x v – m x 0
=mxv


V

Force ‘F’
-V

CHANGE IN MOMENTUM = (m x v) – (- m x v)
= 2 x (m x v)
Force ‘F’ α 2 x (m x v)



v v sinθ
θ
v cosθ

F

-v cosθ CHANGE IN MOMENTUM = (mvcosθ) – (- mvcos θ)
θ -v
= 2 x (mvcos θ)
-v sinθ

Force ‘F’ α 2 (mvcos θ)

WORKING PRINCIPLE OF STEAM TURBINE

ROTATING •Steam at high pressure & temperature is made to pass
BLADE ROW through a set of fixed blade mounted on stationary
body in Casing.

•There will be drop in pressure of the steam across the
fixed blade resulting to very high steam velocity at the
FIXED
exit of fixed blade
BLADE
ROW •The high velocity steam then passes through another
DRIVING row of blades mounted on the rotor shaft
STATIONARY FORCE
BODY/CASING
•The impingement of high velocity steam generates
driving force on these rotating blades which rotate the
rotor.

• A set of fixed blades and rotating blades mounted on
rotor is called stage of turbine. Depending on steam
condition and power output, number of stages in
steam turbine is decided
ROTOR

Main Components of Steam Turbine
1 2 3 4 5 6 7

1
1

8

1. Fixed/Guide Blades 5. Gland seals 9. Governing System
2. Moving Blades 6. Bearing & bearing Pedestal 10.Lub. System
3. Casing 7. Coupling 11.Drain system
4. Rotor 8. Stop & Control Valves 12. C&I System

Rotor is vital element involved in
conversion of kinetic energy of
steam into mechanical energy of
rotation.

Run at high speed depending upon
grid frequency (50Hz,60 Hz).

Subjected to sever stresses i.e.
Centrifugal forces, thermal


Turbine By-Pass System


Generator stator
frame


SHOP WELD PLAN
 Welding engineering department issues shop weld plan to Planning,
Shop floor where actual job is going on.

 The name self indicate that it is a welding plan of actual job – vessel and
it guides to shop floor supervisor and welder that which WPS/PQR shall
use for particular seam.

 Shop welding plan is related to the welding of the job. It provided all the
information regarding weld seam to the welder, as he must well aware of
all required conditions of the welding each seam.

 If company is working under ISO-9000. It has to keep all the activities to
be documented Hence the required documents are made.


 SWP gives the following information regarding the job as related they all seem
to be welded.
◦ Seam numbers
◦ Base metal / P-Number
◦ Joint Detail
◦ Weld process
◦ Layer
◦ WPS No.
◦ PQR No.
◦ F - Number
◦ Pre heat temperature
◦ Inter pass temperature
◦ Position
◦ Customer
◦ Inspection agency
◦ Mfg. Code
◦ Post weld heat treatment
◦ Special notes.

TEST PLAN
 Welding engineering department issues test plan to planning, NDT, and
shop floor for a particular job which is under production.

 In testing plan list of test for particular seam number is given with
reference of ASME and customer specification and also given detail of
production weld test coupon such as type of testing (destructive & Non-
destructive), quantity thickness, For which seam no. required the PTC that
is also described.

 After completion of welding of all seams particular test is carried out as per
testing plan.

 With reference of Test plan the shop supervisor is offered the seam for
testing to NDT department.


 The following manners are given in the test plan:
• Seam wise stage no. and stage description. For testing.
• Extent
• Specification
• Acceptance standard
• Production Test Coupon
o Seam No,
o Thickness
o NDT
o Chem. Analysis.
o Transverse tensile’
o All weld tensile
o Impact test
o Micro/Macro test
• Hardness
• Inspection agencies
 Hydraulic/pneumatic/leak test and other tests TURBINE GENERATORS
L&T MHI

QUALITY CONTROL PLAN
QUALITY CONTROL PLAN
Order: MODEL Drawing No.: Control No.: RJ/GEN/QAP-043
Part No: As per drawing Part Name: GENERATOR STATOR FRAME Dt. 10.06.211
QC Flow Chart Type : Project Items Project Name : Generator Stator Frame Ref. Doc.: Nil
Manufacturing Relevant
Sr. L&T MHI
and Inspection Control Item Document And Frequency Supplier QC Sign Quality Record Remarks
No. TG
Process Procedure
T-Side Block Assy (A42B327)
1 Receiving Mill Sheet Visual Purchase 100% W R/W Mill TC Material All plates shall be
inspection and & Dimension Specification As identification UT tested as
material per drawing JV record mentioned in JV
conformation Standard std. &
identification (P.
No etc. must be
there)**
2 Fit-up & Groove shape, As per drawing 100% W W Fit Up Report All line items as
marking Angle, per drawing no.
inspection Misalignment, A42B327 shall be
Cleaning (Groove inspected at this
Surface) stage.
3 Welding Welder, Welding ASME Sec. IX 100% W … … Welding spatters,
electrode, A35G107 A- under cut etc.
Preheating, KOSHI-R04702 must not be there.
Current/voltage

4 PT test of Flaw detection A-SIKI- 100% W W PT Report For PT, Solvent
completed weld method, ROWB007 removal method
Situation of flaw shall be applied
detection surface

5 Dimensional & Visual, As per drawing 100% W W Dimensional
visual Dimension, Report
inspection Surface
roughness L&T MHI TURBINE GENERATORS

E-Side Block Assy (A42B326)
inspection and & Dimension Specification identification UT tested as
material As per record mentioned in JV
conformation drawing JV std. &
Standard identification (P.
No etc. must be
there)**

7 Fit-up & Groove shape, As per 100% W W Fit Up Report All line items as
marking Angle, drawing per drawing no.
Surface) stage.

Preheating, KOSHI- must not be
Current/voltage R04702 there.

completed method, Situation ROWB007 removal method
weld of flaw detection shall be applied
surface

10 Dimensional & Visual, As per 100% W W Dimensional
visual Dimension, drawing Report
inspection Surface
roughness


Centre Block Assy (A35F896)
inspection and & Dimension Specification identification UT tested as
material As per record mentioned in JV
conformation drawing JV std. &
Standard identification (P.
No etc. must be
there)**

12 Fit-up & Groove shape, As per 100% W W Fit Up Report All line items as
marking Angle, drawing per drawing no.
Surface) stage.

Preheating, KOSHI- must not be
Current/voltage R04702 there.

completed method, Situation ROWB007 removal method
weld of flaw detection shall be applied
surface

15 Dimensional & Visual, As per 100% W W Dimensional
visual Dimension, drawing Report
inspection Surface
roughness


Frame Block Docking Assy (A35G121)
16 Receiving Mill Sheet Visual & Purchase 100% W R/W Mill TC Material All plates shall be
inspection and Dimension Specification As identification UT tested as
material per drawing JV record mentioned in JV
conformation Standard std. &
identification (P.
No etc. must be
there)**

17 Fit-up & Groove shape, As per drawing 100% W W Fit Up Report All line items as
marking Angle, per drawing no.
Surface) stage.
Preheating, KOSHI-R04702 must not be there.
Current/voltage
completed weld method, Situation ROWB007 removal method
of flaw detection shall be applied
surface
20 Final Visual, Dimension, As per drawing 100% W W Dimensional
Dimensional & Surface roughness Report
visual
inspection
21 Surface coating Type of coat, As per drawing 100% W R Painting Report
& painting coating thickness and
Specification
Abbreviation :- W- Witness R- Review
This quality control flow chart & QCL shall be revised as an when required.
Prepared By Checked By Approved By


BILL OF MATERIAL
BILL OF MATERIAL
PROJECT NAME:- GENERATOR STATOR FRAME
Unit Total
Sr Part THK in Qty
Description Material Weight Weight Remarks
No. No. mm unit
(Kg) (Kg)
1 001 Shell Plate 5 SS400P 4 11.50 46.00
2 002 Cooler Adapter 10 SS400P 2 4.8 9.50
3 003 Lead box 10 SS400P 1 5.40 5.40
4 004 Frame Foot 10 SS400P 4 1.25 5.00
5 005 Frame Foot Support 1 8 SS400P 8 0.075 0.06
6 006 Frame Foot Support 2 8 SS400P 12 0.042 0.50
7 007 End Plate 10 SS400P 2 2.5 5.00
8 008 Rib Plate 10 SS400P 2 1.75 3.50
9 009 Flange 10 SS400P 6 0..67 0.40
10 010 Trunion 10 SS400P 4 0.25 1.00
11 011 Man hole 10 SS400P 4 1.25 5.00
12 012 support 10 SS400P 4 2.5 10.00
13 013 Bore Ring 8 SS400P 6 0.083 2.50
14 014 Boring Support 10 SS400P 4 0.025 0.10
15 015 Lifting Lug 10 SS400P 4 0.0375 0.15
Total Weight 97.24


STATOR FRAME MODELFABRICATION SEQUENCE
PROCEDURE

Stator Frame Model fabrication Sequence Procedure
Sr.
Description Planned Date Actual Date Remarks
No.
1 Material Selection 5/3/2012 6/3/2012
2 Marking Of Shell 6/3/2012 8/3/2012
3 Long Seam Marking 7/3/2012 10/3/2012
4 Long Seam Welding On Shell 7/3/2012 10/3/2012
5 Circ. Seam Marking 8/3/2012 10/3/2012
6 Circ. Seam Welding On Shell 8/3/2012 11/3/2012
7 Gas Cutting Of T-Side And E-Side 9/3/2012 12/3/2012
8 Grinding Of Cutting Parts 10/3/2012 13/3/2012
9 Cnc Cutting Of E-Side And T-Side Parts 12/3/2012 153/2012
10 Grinding Of E-Side And T-Side Parts 13/3/2012 15/3/2012
11 Cnc Cutting Of Flanges, Manhole, Trunnion 14/3/2012 16/3/2012
12 Grinding Of Flanges, Manhole, Trunnion 14/3/2012 18/3/2012
13 Marking Of Bore Ring And Rib Plates 15/3/2012 19/3/2012
14 Cnc Cutting Of Bore Ring And Rib Plates 16/3/2012 20/3/2012
15 Grinding Of Bore Ring And Rib Plates 19/3/2012 21/3/2012


16 Set-Up And Assembly Of E-Block Parts 20/3/2012 22/3/2012
17 Welding Of E-Block Parts 21/3/2012 23/3/2012
18 Set-Up And Assembly Of T-Block Parts 22/3/2012 24/3/2012
19 Welding Of T-Block Parts 23/3/2012 24/3/2012
20 Full Welding Of E-Block With Shell 24/3/2012 24/3/2012
21 Full Welding Of T-Block With Shell 24/3/2012 27/3/2012
22 Marking Of outer Components On Shell 26/3/2012 27/3/2012
23 Gas Cutting Of Components 27/3/2012 28/3/2012
24 Assembly Of Bore Ring And Rib Plates 28/3/2012 28/3/2012
25 Horizontal Docking Of Structure 29/3/2012 29/3/2012
26 Tack Weld Of Structure 29/3/2012 29/3/2012
27 Full Welding Of Structure With Shell 29/3/2012 30/3/2012
28 Fit-Up Of Outer Components 30/3/2012 30/3/2012
29 Welding Of Components 31/3/2012 2/4/2012
30 Marking Of Frame Foot And Its Supports 31/3/2012 2/4/2012
31 Welding Of Frame Foot And Its Supports 31/3/2012 3/4/2012
32 End Plate Fit-Up 2/4/2012 3/4/2012


33 End Plate Welding 2/4/2012 4/4/2012
34 Visual Inspection 2/4/2012 4/4/2012
35 Distortion Removal 3/4/2012 4/4/2012
36 Dimension Checking 4/4/2012 4/4/2012
37 Cleaning And Surface Preparation 4/4/2012 4/4/2012
38 Marking Of Supports 5/4/2012 5/4/2012
39 Leveling Of Stator Frame 5/4/2012 5/4/2012
40 Welding Of Supports 5/4/2012 5/4/2012
41 Visual Inspection 5/4/2012 6/4/2012
42 Cleaning And Surface Preparation 5/4/2012 7/4/2012
43 Blasting 6/4/2012 9/4/2012
44 Painting 6/4/2012 10/4/2012
45 Final Inspection 7/4/2012 11/4/2012
46 Packing 9/4/2012 11/4/2012
47 Dispatch 10/4/2012 12/4/2012


BOX PLOT PLAN OF GENERATOR STATOR FRAME
Drawing Material CNC cutting of Fit-up
E-BLOCK
Fabrication 7/3/2012 Selection parts and assembly
8/3/2012 grinding 16/3/2012
14/3/2012
BOX PLOT PLAN OF
GENERATOR
T-BLOCK Fit-up STATOR FRAME MODEL
Fabrication Drawing Material CNC cutting
Selection assembly
7/3/2012 of parts and
8/3/2012
17/3/2012
grinding
14/3/2012
Full Welding of
Gas cutting Final Fit-up Outer Parts
C-BLOCK Material of Shell, of E and T- Full Welding 28/3/2012 Support
Fabrication Drawing Selection Marking of 24/3/2012 cutting and
Grinding on block
7/3/2012 8/3/2012 E and T cutting part welding
18/3/2012
block side 17/3/2012 7/4/2012
12/3/2012

Inner side Marking of Vertical
Fabrication Drawing Borering CNC cutting Assembly of Final Fit Of
of Borering and 7/3/2012 and Rib of Borering Borering and Parts
Rib plate plate and Rib plate 18/3/2012 Blasting
8/3/2012 Rib plate 9/4/2012
16/3/2012

Flanges/ manhole/ CNC
Material Marking on
trunnion Drawing cutting of shell Fit-up on Painting
Selection
Fabrication 7/3/2012 external 9/4/2012
8/3/2012 21/3/2012 shell
items 22/3/2012
16/3/2012

Frame foot/End Material
Drawing Selection CNC cutting Marking, Fit-up Packing
plate
7/3/2012 8/3/2012 of external Set-up 24/3/2012 10/4/2012
Fabrication
items 22/3/2012
19/3/2012

FABRICATION HRS: 34 DAYS Dispatch
TOTAL WEIGHT: 97.24 KGS 10/4/2012


PROCESS PLANNING SHEET
Process Planning Sheet PPS. No. Methods Eng. ref. Rev. No. Page No.
No.
FAB 0 0 Total:
Client Part Name Rev. NO. Drawing No. Material Facility

Projec Stator frame model 0 SS400 Nil
t
Order Process Description Process No. MHI/MELCO Date Estimated Time
No. Reference No.
1 Fabrication. 01# 0 24-Feb-10 34 days

Opn. Process IMAGES Target day Remarks
No.
1 Documentation
Fabrication Drawings 5 REF.OF ACTUAL
DRG.
Inspection record formats
2 Technical standards & work procedures

WPS 1
QCL AND QAP 1
3 MARKING OF SHELL
Marking of Centre line of shell by using the 1
divider and punch mark. LONG SEAM
MARKING and CIRC. SEAM MARKING
4 Cutting & edge preparation
Gas cut the of shell as per e-block and t-block 1
dimensions
5 CNC CUTTING OF E-SIDE AND T-SIDE
PARTS
Cutting as per design requirement and grinding 2
of all cut-out of parts after cutting.

6 CNC CUTTING OF FLANGES, MANHOLE, TRUNNION

Cutting as per design requirement and grinding of all cut-out of parts after 2
cutting.
7 MARKING OF BORE RING AND RIB PLATES
Marking of the rib plate as per the design and cut-out the plate in CNC 2
machine then grinding the all parts.

8 SET-UP AND ASSEMBLY OF E-BLOCK PARTS

all cut-out parts are set-up properly and assemble the structure of E-block 2

9 WELDING OF E-BLOCK PARTS
All parts in joint by the GTAW process as per the welding design

10 SET-UP AND ASSEMBLY OF T-BLOCK PARTS 3

All cut-out parts are set-up properly and assemble the structure of T-block

11 WELDING OF E-BLOCK PARTS
All parts is joint by the GTAW process as per the welding design 1

12 FULL WELDING OF E-BLOCK WITH SHELL
The E-block structure is welded with shell by using GMAW process. 1

13 FULL WELDING OF T-BLOCK WITH SHELL
The T-block structure is welded with shell by using GMAW process. 1

14 FIT-UP OF OUTER COMPONENTS
Fit-Up THE FLANGES, MANHOLE, TRUNNIONS IN THE OUTER SIDE OF 1
SHELL
15 WELDING OF COMPONENTS
Full welding of components by using GTAW process. 1

16 MARKING OF FRAME FOOT AND ITS
SUPPORTS
MARKING OF FRAME FOOT AND ITS SUPPORTS 1
ON THE SHELL
17 WELDING OF FRAME FOOT AND ITS
SUPPORTS
All cut-out parts of frame foot and supports 1
welded by GMAW welding process.
18 END PLATE FIT-UP AND WELDING
Leveling of shell and end plate with respect of 1
design and full welded
19 VISUAL INSPECTION
After all welding complete visual check 1
inspection
20 DISTORTION REMOVAL
Remove all NDT points by grinding and chipping 1
hammer.
21 MARKING OF SUPPORTS
LEVELLING OF STATOR FRAME
Marking and leveling of supports then full
welding
22 CLEANING AND SURFACE PREPARATION
CLEANING AND SURFACE PREPARATION OF ALL 1
WELDED PARTS AND COMPLETE SHELL.
23 BLASTING
BLASTING USING SMALL PRESSURE APPLIED 1
24 PAINTING
PAINTING OUTER AND INNER SIDE 1
BYMANUALLY.
25 DISPATCH 1
26 PACKING 1

SOME SPECIFIC TERMS USED IN WPS
Welding Variables
◦ Essential variables.
◦ Supplementary essential variable.
◦ Non-essential variables.

P – Numbers:
◦ To reduce the number of welding procedure qualification required, base
metals have been assigned P – Numbers.

F – Numbers:
◦ F Numbers are used for filler metal designation and grouping of electrodes &
welding rods.
◦ It is based essentially on their usability characteristics.

A – Numbers:
◦ A – Numbers are used to identify the weld metal chemical composition of
ferrous metals.

CONT…

Joints
• The WPS describe some variable like groove design ,backing etc.,

Base Metals
• It is essential variables for all welding processes.
• A change in a base metal thickness beyond the range qualified in
table (As per qw-4541) requires the requalification of WPS.

Filler Metal
• Filler metal should be selected which is compatible to base metal
chemical composition (Sec.II_A/B). They must have same/similar
chemical composition.
• For filler metal chemical composition, we have the refer ASME SEC-II
C.


CONT…

Position
• Position is supplementary essential variable.
• 1G, 2G, 3G, etc., are different types of welding positions (as per QW-461
Sec IX)

Preheat
• It can be determine from ASME SEC VIII, Division – 1, Appendix – R.

PWHT
• ASME SEC – VIII, DIV- I, Per. UCS-56 describes PWHT temperature and
time range for specific material with respect to P – Number.


CONT…

Gases
• Three types of gases are described in WPS.
o Shielding gas.
o Backing gas.
• Trailing gas

Electrical Characteristics
• ELECTRICAL CHARACTERISTICS (QW – 409)
• We have to write Current, Polarity, and Voltage as electrical
characteristics.

Technique
• It is determined manually with respect to joint design, material type
material thickness etc

WPS
QW-482 WELDING PROCEDURE QUALIFICATION (WPS)

Supporting
WPS NO: 1 DATE: 12-3-2012 -
PQR No(s)

Welding
Revision: RO SMAW
Process
Date: 12-3-2012 Type MANUAL
JOINTS (QW-402)
Groove Design As per Drg.
Backing: (Yes/No) Yes
Backing Material (type) Base metal/Weld metal
Other -
BASE METALS (QW-403)
MATERIAL 1 MATERIAL 2

P. No. 1 P. No. 1

Group No. 1 Group No. 1

Specification/Grade - Specification/Grade -

Thickness Range: (mm):5 to 200 mm

Base Metal: ss-400 Groove: all Fillet ANY

Deposited weld thickness: 200 mm MAX SMAW 6 Fillet ANY

Other: 13 mm maximum weld deposition in single pass

FILLER METALS(QW-404)
Process SMAW
F. No. 4
A. No. 1
SFA
Spec No.
5.1

AWS No. (class) E 7018

Φ 2.5,
Size of filler metals (mm) 3.15,
4,
Electrode Flux (class) NA
Flux Trade name NA
Consumable Insert NA
Chemical composition NA
Other NA
POSITIONS (QW-405)
Process(es): SMAW
Position of Groove: ALL F-Flat
Welding Progression: uphill
Position of Fillet: ALL H-Horizontal

V-Vertical
Other None
O-Overhead

PREHEAT (QW-406)
Preheat Temp. (Min):ºC 150 ºC
Interpass Temp. (Max):ºC 350 ºC
Preheat Maintenance: During Welding
Other NA

POST WELD HEAT TREATMENT (QW-407) ELECTRICAL CHARACTERISTICS(QW-409)
Type of PWHT Current(AC or Dc) DC
TEMP. Range: ºC Polarity (EN or EP) EP
Amps (Range) 70-155 A
Soaking/Holding Time
Voltage (Range) 20-30 V

Rate of Heating Tungsten Type & Size NA

Rate of Cooling Mode of Metal Transfer NA

NA
Others: Electrode wire feed
GASES (QW-408)
Flow
% Composition
Rate(LPM)
Shielding Gas NA NA
Backing/Purging Gas NA NA
Trailing Gas NA NA
Other NA NA
TECHNIQUE (QW-410)
String/Weave Bead Gas Cup Size NA
Travel Speed (range) Cont. Tube Work Dist. NA

Multiple/Single Electrode Multi/Single Pass (per side) Multi Pass
Oscillation NA
Closed to out chamber NA
Cleaning By wire brush
Method of Gouging/Back chip By grinding
Other NA

Filler Metal Current
Max Min
Flux Travel Speed
Weld Dia Volt heat Bead
Process Trade Range
Type & Amp. Range input
Layer Class (mm Name Length
Polarity Range (mm/min)
) (KJ/mm) (mm)

2.5 NA DCEP 70-90 20-30 - - -
ALL PASS

E-7018 3.15 NA DCEP 100-140 20-30 - - -
SMAW
4 NA DCEP 155-190 20-30 - - -


QW-482 WELDING PROCEDURE SPECIFICATION (WPS)
Supporting PQR
WPS NO: 3 DATE: 12-3-2012 -
No(s)

Revision: RO Welding Process GMAW

Date: 12/3/2012 Type Machine
JOINTS (QW-402)
Backing: (Yes/No) with and without
Backing Material (type) Base metal/Weld metal
Other -
P. No. 1 P. No. 1

Group No. 1 Group No. 1

Specification/Grade SS-400 Specification/Grade SS-400

Thickness Range: (mm)
5mm to 200
Base Metal: Groove Fillet ANY
mm
5 mm to 200
Deposited weld thickness GMAW Fillet ANY
mm
Other: None


Process GMAW

F. No. 6

A. No. 1

Spec No. 5.28

AWS No. (class) ER 70S 6

Size of filler metals (mm) Φ 1.6

Electrode Flux (class) Na

Flux Trade name NA
Other NA
POSITIONS (QW-405)
Process(es): GMAW
Position of Groove: all
F-Flat
Welding Progression: NA
Position of Fillet: F,H,V,O H-Horizontal

V-Vertical
Other None
O-Overhead
PREHEAT (QW-406)
Preheat Temp. (Min):ºC 150*
Interpass Temp. (Max):ºC 350*
Preheat Maintenance: During welding
Other NA
Prepared By Reviewed By Approved By

WPS No:


Type of PWHT - Current(AC or Dc) DC
TEMP. Range: ºC - Polarity (EN or EP) EP
- Amps (Range) -
- Voltage (Range) -
Rate of Heating - Tungsten Type & Size NA
Rate of Cooling - Mode of Metal Transfer SPRAY
- NA
Others: Electrode wire feed
-
GASES (QW-408)

Gas % Composition Flow Rate(LPM)

Shielding Gas Ar-Co2 80% to 20% 14 to 24
Backing/Purging Gas NA NA NA
Trailing Gas NA NA NA
Other NA NA NA
TECHNIQUE (QW-410)
String/Weave Bead String Gas Cup Size NA

30-200 Cont. Tube Work
Travel Speed (range) 15-22mm
mm/min Dist.

Multi/Single
Multiple/Single Electrode Single Multi pass
Pass (per side)

Oscillation None
Closed to out chamber None
Cleaning With wire brush
Method of Gouging/Back chip -
Other - L&T MHI TURBINE GENERATORS

V
Filler Metal Current o Min
Flux lt Travel Speed Max
Weld R Bead
Process Trade Range heat input
Layer Dia a Length
Name Type & Amp. (mm/min)
Class n (KJ/mm)
(mm) Polarity Range
g (mm)
e
1
8
ER 70S 30-
- GMAW 1.6 - DCEP 180-280 - -
6 200mm/min
3
0

Prepared by Reviewed by Approved by


QW-482 WELDING PROCEDURE SPECIFICATION (WPS)111
DATE: 12-3- Supporting PQR
WPS NO: 5 -
2012 No(s)
Revision RO Welding Process GTAW
Date 12-3-2012 Type Manual
JOINTS (QW-402)
Backing: (Yes/No) No
Backing Material (type) NA
Other -


P. No. 4 P. No. 4

Group No. 1,2 Group No. 1,2

Specification/Grade - Specification/Grade -

Thickness Range: (mm)

Base Metal: Groove (5-200mm) Fillet ANY

Deposited weld thickness GTAW (5-200mm) Fillet ANY

Other: None

Process GTAW
F. No. 6
A. No. 1
Spec No. 5.18
AWS No. (class) ER 70S-2
Size of filler metals (mm) Φ 1.6, 2.4
Electrode Flux (class) NA
Flux Trade name NA
Other NA
POSITIONS (QW-405)
Process(es): GTAW
F-Flat
Position of Groove: ALL
Welding Progression: Uphill H-Horizontal
Position of Fillet: ALL
V-Vertical

Other None O-Overhead


PREHEAT (QW-406)
Preheat Temp. (Min):ºC -
Interpass Temp. (Max):ºC -
Preheat Maintenance: -
Other -
WPS No:
Type of PWHT - Current(AC or Dc) DC

TEMP. Range: ºC - Polarity (EN or EP) EN

- Amps (Range) -
- Voltage (Range) -

Rate of Heating - Tungsten Type & Size EWTh-2

Rate of Cooling - Mode of Metal Transfer NA

Other - Electrode wire feed NA

GASES (QW-408)-

Gas % Composition Flow Rate(LPM)

Shielding Gas Argon 99.995% 8-12
Backing/Purging Gas NA NA NA
Trailing Gas NA NA NA
Other NA NA NA


TECHNIQUE (QW-410)
String/Weave Bead String Gas Cup Size Φ 6.0-10.0mm dia
Travel Speed (range) NA Cont. Tube Work Dist. NA
Multi/Single Pass (per
Multiple/Single Electrode Single Multi Pass
side)
Oscillation None
Closed to out chamber None
Cleaning With wire brush
Method of Gouging/Back chip By grinding
Other -
Filler Metal Current
Flux Travel Max Min
Trad Speed heat
Weld Volt Bead
Process Dia e Type & Amp. Range input
Layer Class Range Length
(mm) Nam Polarity Range (mm/mi (KJ/mm
e n) ) (mm)

Root GTAW ER 80S-G 2.4,2.5 NA DCEN 80-120 10-18 - - -

Rest GTAW ER 80S-G 2.4,2.5 NA DCEN 110-180 10-18 - - -

All SMAW - - NA - - - - - -
All SMAW - - NA - - - - - -
Prepared by Reviewed by Approved by


FUNCTION OF GENERATOR STATOR FRAME


PARTS OF GENERATOR STATOR FRAME


BORE RING
• bore ring is mainly use for the supporting the core bolt and
balancing the rotor All fabrication process complete after send to
assembly shop.

Clamping
arrangement

Outer ring

Inner ring


After Leveling & centering of bore ring do tack weld elastic plate to bottom Frame plate.

Then ｐlace new Frame Plate Above it. Do leveling & centering of same frame plate. Do tack weld
it with elastic plate below it. Additional temporary support can also be utilize.

Then place next `Bore ring + Elastic Plate` and repeat the above process.

And so on complete the Centre block assembly fit-up. L&T MHI TURBINE GENERATORS

FRAME FOOT
• Frame foot is use for the foundation of the generator.


LEAD BOX
• Lead box mainly use the Supply the lead outside inside


PROCESS
 Marking frame plate
 Setting end plate (T side)
 Mounting ribs of T side block (1st set)
 Mounting frame plate of T side block
 Mounting ribs of T side block (2nd set)
 Mounting 1st frame plate of center block
 Partial welding ribs of T side block (1st set)
 Mounting shell plate of T side block
 Gas cutting hole for lead box adapter
 Mounting of 1st bore ring


CONT…

 Mounting of 2nd frame plate of center block
 Welding inside frame
 Cleaning welding portion, Painting of angle, pipe and flexible beam
support
 Mounting shell plate of center block
 Welding shell plate center block
 Mounting lead box adapter
 Welding lead box adapter


TRUNNION
• Lifting the generator


COOLER ADAPTER
• Cooler adapter is mainly use to cooling the steam.


PROCESS
 Marking frame plate
 Setting end plate (E side)
 Mounting ribs of E side block (1st set)
 Mounting frame plate of E side block
 Mounting shell plate of E side block
 Mounting ribs of E side block (1st set)
 Gas cutting hole for cooler adapter
 Welding inside frame in flat position
 Turnover
 Welding inside frame in flat position


foram

Recomendados

Recomendados

Más contenido relacionado

La actualidad más candente

La actualidad más candente (20)

Destacado

Destacado (20)

Similar a foram

Similar a foram (20)

Último

Último (20)

foram