This document provides an overview of turbine erection training conducted at the 2x700 MW Rajpura Thermal Power Plant in Punjab, India from June 20th to August 10th, 2013. It outlines the 12 step turbine erection flow chart that was followed, including centering the turbine foundation, installing components like the LP outer casing and HIP module, installing bearings and rotors, final assembly procedures, grouting, and oil flushing. The training aimed to teach trainees how to properly erect and align the turbines according to specifications.

1. SUMMER TRAINING AT 2X700 MW
RAJPURA THERMAL POWER
PLANT, PUNJAB
LARSEN & TOUBRO
LARSEN & TOUBRO

2. MHI Turbine Generators
INTRODUCTION
TRAINING TOPIC : TURBINE ERECTION
•
• TRAINING LOCATION : 2X700 MW RAJPURA THERMAL POWER
PLANT, PUNJAB
TRAINING DURATION : 20.06.2013 TO 10.08.2013
•
•
LARSEN & TOUBRO
It’s all about Imagineering

3. TURBINE ERECTION FLOW CHART
STEP-1
Centering Of
Turbine Foundation
STEP-2
Setting of levelling Plates
and Levelling Wedges
STEP-3
Setting of Turbine
seatingPlates
S
S
T
T
E
P
E
P
-
-
4
4
IInnsstaltalllatatiionon
of
ofLP
LP O
Ou
ute
ter
r
ccasasiinngg
STEP-4
Installation of LP
Outer casing
SSTTEP
EP
-
5
-
5
I
In
ns
stal
tall
lat
ati
ion
on of
of
H
HI
IP
P M
Mod
odu
ul
le
e
an
and
d H
HP
P/
/I
IP
P
PPeeddeesstaltal
STEP-5
Installation of HIP
Module and HP/IP
Pedestal
SSTTEP
EP
-
6
-
6
Levelling & centerin
Of LP-1 and LP-2
Casing
STEP-6
Levelling & centeringg
Of LP-1 and LP-2
Casing
SSTTEP
EP
-
7-
7
IInnsstaltalll
b
b
e
e
a
r
a
r
i
i
n
n
g
g
s
sanandd
RRotorotorss
STEP-7
Install bearings
and Rotors
SSTETEP
P
-
8
-
8
Provisional centering
Of LP-1 & LP-2
STEP-8
Provisional centering
Of LP-1 & LP-2
SSTTEP
EP
-
9-
9
PPrroviovissiiononalal
c
c
e
e
n
n
t
t
e
e
r
r
i
i
n
n
g
go H
H
I
I
P
P&
&
LP
LP
1
1 R
Roto
otor
r
P
STEP-9
rovisional centering off
HIP & LP 1 Rotor
SSTTEPEP-10-10
Installation of inner
Parts of LP casing
(Pre Assembly)
STEP-10
Installation of inner
Parts of LP casing
(Pre Assembly)
SSTTEPEP-1
1-1
1
2
2n
nd
d c
ce
en
nt
te
er
ri
in
ng
g
of
of H
HI
IP
PT
Tu
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rb
bi
in
ne
e –
–
L
LP
P T
T
u
u
r
r
b
b
i
i
n
STEP-11
2nd centering of HIP
Turbine –LP Turbinnee
SSTTEPEP-12-12
F
Fi
in
nal
al A
As
ss
se
em
mb
bl
ly
y
STEP-12
Final Assembly
STEP-15
Oil Flushing
S
STE
TEP
P-
13
-13
Grouting
STEP-14
Checking Final
Coupling alignment
And coupling
STEP-16
Final assembly of
Pedestal Turning gear
& others
MHI Turbine Generators

4. CENTERING OF TURBINE FOUNDATION
•
•
•
•
•
The basic centerline of the turbine and generator
foundation shall be confirmed according to the
foundation drawing.
The position of foundation bolts and anchor blocks
from the centerline of turbine shall be confirmed and
recorded.
The basic centerline of turbine shall be check by
optical scope.
Optical scope shall be on referance elevation mark.
Top surface of the foundation shall be chipped.
MHI Turbine Generators

5. MHI Turbine Generators

6. SETTING OF LEVELLING PLATES & LEVELLING
WEDGES
• Leveling plates and leveling wedges shall be fixed
by grouting to their correct position with a level
wedge shall be consider with “Rotor alignment
curve”.
MHI Turbine Generators

7. SETTING OF TURBINE SEATING PLATES
•
•
•
•
•
Before setting of seating plate, contact should be cleaned and
each seating plate shall be located and be set on its correct
position.
Adjusting bolts shall be installed on the seating plate with
thread paste.
After seating plates in place, a piano wire shall be stretched on
between the centerline of the turbine, then accurate centering
of each seating plate shall be made according to this piano
wire. Tolerance shall be not more than +/-2mm from centerline.
Elevation tolerance : 0~ -0.5 mm
Each seating plate shall be adjusting bolts and leveling
wedges. To measure the height of the seating plate to surface,
using straight-edge with level vial. Permissible tolerance is
within 0.25MM/M.
MHI Turbine Generators

8. SETTING OF TURBINE SEATING
PLATES
Seating plate
Adjusting bolt
MHI Turbine Generators

9. INSTALLATION OF LP LOWER OUTER
CASING
•
•
The machined surface of seating plate , machined
contact lower surface of horizontal joint and vertical
joint shall be cleaned before installation of LP
turbine. And checked to find damage such as
scratch. And if scratches are found surface shall be
smoothed up by oil stone before installation.
Surface of seating plates shall be thinly coated with
anti-seazing compound is equivalent to Molykote G-
n.
MHI Turbine Generators

10. INSTALLATION OF LP LOWER OUTER
CASING
Guide Pillar
MHI Turbine Generators

11. INSTALLATION OF HP PEDESTAL & HIP MODULE
•
•
•
The machined surface of seating plate , machined
contact lower surface of horizontal joint and vertical
joint shall be cleaned before installation of HIP
Pedestal. And checked to find damage such as
scratch. And if scratches are found surface shall be
smoothed up by oil stone before installation.
Surface of seating plates shall be thinly coated with
anti-seazing compound is equivalent to Molykote G-
n.
Prior to installing the HIP module, both side of the
centering beam shall be fitted to LP-1 pedestal and
HP pedestal temporary.
MHI Turbine Generators

12. 3D VIEW OF HIP PEDESTAL SEATING PLATE
& HIP PEDESTAL
MHI Turbine Generators

13. HIP Extension Shaft
HIP Pedestal
HIP Extension Shaft
Guide Pillar for HIP Module
MHI Turbine Generators

14. LEVELLING & CENTERING OF HIP, LP1 AND LP2
CASING
•
•
•
Lower casing shall be adjusted to level and elevation at
the horizontal joint using automatic/ level edge with level
vial. Adjustment shall be performed using jacking bolts,
levelling wedge and shim liner of seating plate. Then the
target level of horizontal joint of LP casing shal be with
0.25mm/m.
Piano wire shall be re-set the centerline of turbine
generator. Each casing center (LP-2 casing,LP-1 casing)
shall be aligned and installed with scale within 1 mm
target to piano wire as standard line by moving casing
and seating plate together.
Finally, relative location of each part (HP pedestal, HIP
casing,LP-1 casing, LP-2 casing) should be measured the
distance from center line of each parts.
MHI Turbine Generators

15. Levelling of HIP Pedestal by
optical scope
HIP Pedestal
Seating plate
Leveling Wedge
MHI Turbine Generators

16. INSTALL BEARING
• Prior to installation of rotor No 1 and No 2 bearings shall
be installed, and each bearing (No. 3. No. 4, No.5, No.6)
shall be installed with sperical key. And each bearing
shall be conformed contact mark with Blue check paint
so that there is more than 75% contact.
Bearing
MHI Turbine Generators

17. INSTALL LP ROTOR
MHI Turbine Generators

18. Contact check
Blue paste apply on
Journal
Journal
Bearing
Guide Pillar
Bearing Bottom
surface
Jacking Oil Inlet
MHI Turbine Generators

19. PROVISIONAL CENTERING OF LP2 TO LP1 ROTOR
•
•
•
•
•
This alignment work shall be started from LP-2 turbine rotor
level, because LP-2 Turbine is axial center and zero base of this
train.
Each rotor has to be aligned at same time according to
elevation.
It is described that centering work of LP-2 ~LP-1 .
Measure LP-2 rotor level on top of No.5 and No. 6 bearing
journal.
And rotor level shall be adjusted by seating plate for pedestal
utilizing jacking bolt, levelling wedge and/or shim liner, if
necessary.
MHI Turbine Generators

20. PROVISIONAL CENTERING OF LP 1 to HIP TURBINE
•
•
Measure LP-1 rotor level on top of No.3 and No.4 bearing
journal.
And rotor level shall be adjusted by seating plate for
pedestal utilizing jacking bolt,leveling wedge and/or shim
liner, if necessary.
MHI Turbine Generators

21. ALIGNMENT OF LP-2~LP-1 TURBINE ROTOR
LP 1 Rotor
MHI Turbine Generators

22. BEARING ALIGNMENT CURVE
MHI Turbine Generators

23. INSTALLATION INNER PARTS OF LP TURBINE
(PRE-ASSEMBLY)
•
•
•
Prior to install inner parts, it’s shall be cleaned by
solvent such as kerosene to remove anti-corrosion
coat. Also machined surface shall be conformed
smooth by oilstone. Finally, nerrow areas of inner
parts such as bolt hole, keyhole,groove and drain
hole shall be cleaned by air blow.
Before lifting Inner casing check sealing, D cycle,
and chain block it should not damage. Use two
sealing and Two chain block for lifting Inner casing.
Check Its radial key it should be properly welded.
MHI Turbine Generators

24. Check Its radial key it should
be properly welded
Lift the inner lower casing and check
level it should be equal in four
machine corner if not equal then make
equal by chain block.
Radial Pin
MHI Turbine Generators

25. Install Inner casing carefully.
Install Steam chamber
Install Blade Ring Install Sp. Stationary Blade
MHI Turbine Generators

26. Install Flow Guide
MHI Turbine Generators

27. RECORD OF CLEARANCE
•
•
•
•
•
•
•
•
•
Prior to install LP-1, LP-2 rotors, lead wire shall be put on
each stage labyrinth fin to measure clearance.
LP 1 and LP 2 Rotor shall be installed.
Radial clearance (Right & left) & Axial clearance
measured by taper guage and Fillar guage.
Install Upper inner casings to measure upper labyrinth
clearance.
Tighten casing bolt to fit upper and lower casing.
upper inner casings and rotors shall be taken out from
the casing. Lead wire shall be taken out for measurement.
Each clearance shall be considered about “Rotor and
casing deflection”.
LP-1 and LP-2 Rotor shall be installed again.
Amount of rotor movement from K position and total float
of each rotor shall be measured and recorded.
MHI Turbine Generators

28. INSTALL LEAD WIRE ON ROTOR AND INNER CASING
Instal Lead wire
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29. Reamar bolt tightning
Lifting of inner casing
Lead Wire remove
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30. HIP INTERNALS
Thermal Shield (IP)
IP Blade Ring
Dummy Ring #1 (MS)
MHI
HP INNER CASING
Turbine Generators

31. MHI Turbine Generators
2nd CENTERING OF TURBINE
•
•
•
•
The centering of LP 2 turbine and LP 1 turbine shall be carried
out by movement of LP-1 rotor.
The centering of LP 1 turbine and HIP turbine shall be carried
out by movement of HIP rotor.
The centering of LP 2 turbine and generator shall be carried out
by movement of the generator rotor.
Zero points marked on the each rotor shall be turned through
180 degree and placed at the bottom and the clearance
between the matching coupling faces measured.
Alignment of LP 2~ LP 1

32. SETTING OF THE ADJUSTING LINER & BUSH FOR
TIE BEAM
•
•
The clearance between Tie beam and casing will be checked
and recorded.
After insert of the pin for Tie beam, the bush shall be machined
to its regular thickness at the site and shall be set. After
setting, the bush shall be tack welded to lock.
MHI Turbine Generators

33. SEATING OF THE ADJUSTING LINER FOR ANCHOR
BLOCKS
•
•
•
Before setting of the adjusting liner for anchor block, the
inclination of surface of anchor blocks shall be conformed.
( Tolerance of inclination of surface +/- 1.5mm )
After confirmation of the inclination of anchor blocks. The
adjusting liners for anchor blocks shall be machined to its
regular thickness at site.
Adjjusting Liinersettttiing Adjjusting Liiner Machiiniing
MHI Turbine Generators

34. FINAL ASSEMBLY
•
•
After completion of the measurements and verification of
clearance, final assembly shall be commenced. Each parts
shall be cleaned by compressed air prior to the final assembly.
All Inner casing stud bolt will be tightned by Hot Tightning.
Blade ring Install Steam chamber Install
MHI Turbine Generators

35. Inner casing Install
Bolt Tightning
MHI Turbine Generators

36. Outer casing
Flow Guide inside OC Outer Casing installation
MHI Turbine Generators

37. Step 12
Guide Pillar
Level Checking
Bolt Tightning
MHI Turbine Generators

38. Guide Pillar
Level Checking
Bolt Tightning
MHI Turbine Generators

39. GROUTING
•
•
•
•
After completion of 2nd centering of turbine and
generator the grouting stopper shall be installed
around the turbine casing, pedestal and generator.
Grouting shall be carried out when the tubine has
been assembled and is loaded with almost all related
weightupon it.
Cleaned the places to be grouted by blowing air and
washing with water.
Fill the clerance between foundation bolt and
sleeves with grout just before grouting.
MHI Turbine Generators

40. CHECKING OF FINAL COUPLING ALIGNMENT
AND COUPLINGS
 After completion of installing the turbine, couplings of the
turbine to generator shall be checked for HIP=LP-1=LP-
2=GEN alignment and be readjusted if necessary.
 Coupling reamer bolts shall be installed Tightened and
controlled by streatched length of bolts,Tightened value of
coupling reamer bolts
– HIP ~ LP-1 Coupling Bolts = 0.375 ~ 0.431mm
– LP-1 ~ LP-2 Coupling Bolts = 0.432~ 0.497mm
– LP-2 ~ GEN Coupling Bolts = 0.623 ~ 0.717mm
 Thrust bearing assembly and clearance check.
MHI Turbine Generators

41. OIL FLUSHING, FINAL ASSEMBLY OF
PEDESTAL, TURNING GEAR, COUPLING
GUARD AND OTHERS
•
•
•
•
•
 Oil Pipping Flushing
 The purpose of oil flushing prior to operation of turbine
generator is to flush from oil system of foreign material
wich instruded in the system during the installation stage.
After completion of Oil flushing, Top half of each Journal
bearing and thrust bearing shall be installed finally.
Turbine supervisiory equipment (differential expansion pick up,
vibration pick up, essentricity pick up, speed pick up, etc) and
other accessories shall be installed finally.
Coupling Guard (HIP,LP-1/LP-2,GEN) shall be set.
Bearing cover and pedestal cover shall be installed.
Turning device shall be set according to the designed back
lash & tooth contact obtained and set dowel pin.
MHI Turbine Generators

42. MHI Turbine Generators