Turbine Erection Turbine Erection Turbine
gerrard3896
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Aug 15, 2024
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About This Presentation
Turbines Erection
Slide Content
26 May 2012 PMI Revision 00 1
TURBINE
ERECTION
TURBINE
ERECTION
26 May 2012 PMI Revision 00 2
HP Turbine
IP Turbine
HP Turbine
IP Turbine
26 May 2012 PMI Revision 00 3 LP Turbine
Brg
Brg
26 May 2012 PMI Revision 00 4
Salient Features Of Turbine Erection
•The fore most activity before taking up the
work is the safe working conditions. Thus
we should first assemble temporary railing
and covers before the start of the job
•Remove construction material & sweep the
foundation well. A proper foundation is of
utmost importance for proper operation of
the machine. A hammer test is to be carried
to detect any flaw / void in the concrete
layer. An ultrasonic testing of the TG deck
should also be carried out if possible. No
looseness below the base plates is
acceptable
Salient Features Of Turbine Erection
•The fore most activity before taking up the
work is the safe working conditions. Thus
we should first assemble temporary railing
and covers before the start of the job
•Remove construction material & sweep the
foundation well. A proper foundation is of
utmost importance for proper operation of
the machine. A hammer test is to be carried
to detect any flaw / void in the concrete
layer. An ultrasonic testing of the TG deck
should also be carried out if possible. No
looseness below the base plates is
acceptable
26 May 2012 PMI Revision 00 5
26 May 2012 PMI Revision 00 6
Salient Features Of Turbine Erection
(Contd.)
•FOUNDATION CHECK : check accuracy of
size, elevation & axiality of foundation for
conformance the erection drawing
•Check all contact surfaces & openings for
turbine, generator etc., Holes for anchor
bolts. Record final dimensions & make a
protocol
•Check, mark & record main reference point
(absolute floor level) for height against
building wall or foundation pillar
Salient Features Of Turbine Erection
(Contd.)
•FOUNDATION CHECK : check accuracy of
size, elevation & axiality of foundation for
conformance the erection drawing
•Check all contact surfaces & openings for
turbine, generator etc., Holes for anchor
bolts. Record final dimensions & make a
protocol
•Check, mark & record main reference point
(absolute floor level) for height against
building wall or foundation pillar
26 May 2012 PMI Revision 00 7
26 May 2012 PMI Revision 00 8
26 May 2012 PMI Revision 00 9
26 May 2012 PMI Revision 00 10
Salient Features Of Turbine Erection
(Contd.)
•BASE PLATES & BEARING PEDESTALS :
LAYING The base plates are designed to transfer
uniformly all forces & vibrations caused by the
operation of the machine.The pedestal are aligned
as the deflection curve of the rotor. The base plates
are leveled with help leveling screws provided below
the base plate
Salient Features Of Turbine Erection
(Contd.)
•BASE PLATES & BEARING PEDESTALS :
LAYING The base plates are designed to transfer
uniformly all forces & vibrations caused by the
operation of the machine.The pedestal are aligned
as the deflection curve of the rotor. The base plates
are leveled with help leveling screws provided below
the base plate
26 May 2012 PMI Revision 00 11
26 May 2012 PMI Revision 00 12
26 May 2012 PMI Revision 00 13
•ANCHOR BOLTS FOR BASE plates :they are long through
bolts for fastening the machine / base plates to the
foundation. They are stretch elongated by specified length
by the help of the bolt tensioning device.Normally diagonally
opposite two bolts are tightened & locked subsequently
Salient Features Of Turbine Erection
(Contd.)
•ANCHOR BOLTS FOR BASE plates :they are long through
bolts for fastening the machine / base plates to the
foundation. They are stretch elongated by specified length
by the help of the bolt tensioning device.Normally diagonally
opposite two bolts are tightened & locked subsequently
Salient Features Of Turbine Erection
(Contd.)
26 May 2012 PMI Revision 00 14
26 May 2012 PMI Revision 00 15
26 May 2012 PMI Revision 00 16
•ANCHOR BOLTS FOR BASE plates :they are long through
bolts for fastening the machine / base plates to the
foundation. They are stretch elongated by specified length
by the help of the bolt tensioning device.Normally diagonally
opposite two bolts are tightened & locked subsequently
Salient Features Of Turbine Erection
(Contd.)
•ANCHOR BOLTS FOR BASE plates :they are long through
bolts for fastening the machine / base plates to the
foundation. They are stretch elongated by specified length
by the help of the bolt tensioning device.Normally diagonally
opposite two bolts are tightened & locked subsequently
Salient Features Of Turbine Erection
(Contd.)
26 May 2012 PMI Revision 00 17
26 May 2012 PMI Revision 00 18
26 May 2012 PMI Revision 00 19
26 May 2012 PMI Revision 00 20
26 May 2012 PMI Revision 00 21
26 May 2012 PMI Revision 00 22
26 May 2012 PMI Revision 00 23
26 May 2012 PMI Revision 00 24
26 May 2012 PMI Revision 00 25
26 May 2012 PMI Revision 00 26
26 May 2012 PMI Revision 00 27
Salient Features Of Turbine Erection
(Contd..)
• ALIGNMENT :align the base plates in zero position
as per the deflection curve. The location is fixed in
longitudinal & transverse axes using plumb & piano
wires.The levels are fixed using the leveling
instrument such as the dumpy level or by scale &
water tubes and final levelling is done by the help of
precision spirit level.Normally bearing pedestal #4
acts as the zero level for the turbine.The base plates
& pedestals are then tightened with spanners for
taking up the grouting
Salient Features Of Turbine Erection
(Contd..)
• ALIGNMENT :align the base plates in zero position
as per the deflection curve. The location is fixed in
longitudinal & transverse axes using plumb & piano
wires.The levels are fixed using the leveling
instrument such as the dumpy level or by scale &
water tubes and final levelling is done by the help of
precision spirit level.Normally bearing pedestal #4
acts as the zero level for the turbine.The base plates
& pedestals are then tightened with spanners for
taking up the grouting
26 May 2012 PMI Revision 00 28
26 May 2012 PMI Revision 00 29
Salient Features Of Turbine Erection
(Contd..)
•Grouting: The grouting of the base plates &
pedestals is carried using shrink free
grouting cement which is intended to ensure
uniform transmission of mass and vibration
of the machine on the foundation.The
activity is carried with great care as the
operation behavior of the machine depends
largely on workmanship while carrying out
the assembly of the load bearing
components
• Bolt tensioning:
Salient Features Of Turbine Erection
(Contd..)
•Grouting: The grouting of the base plates &
pedestals is carried using shrink free
grouting cement which is intended to ensure
uniform transmission of mass and vibration
of the machine on the foundation.The
activity is carried with great care as the
operation behavior of the machine depends
largely on workmanship while carrying out
the assembly of the load bearing
components
• Bolt tensioning:
26 May 2012 PMI Revision 00 30
26 May 2012 PMI Revision 00 31
Salient Features Of Turbine Erection
(Contd..)
•COUPLINGS: coupling on turbine shaft are generally rigid couplings.
The couplings are used to connect two shafts to form a shaft
assembly. The couplings are so designed so as to perform the
following two functions:
•a)the dimensions & design is such that it is capable of transmission of
all torque encountered during its service.
• b) The coupling must not influence the smooth running of the shaft
assembly
Salient Features Of Turbine Erection
(Contd..)
•COUPLINGS: coupling on turbine shaft are generally rigid couplings.
The couplings are used to connect two shafts to form a shaft
assembly. The couplings are so designed so as to perform the
following two functions:
•a)the dimensions & design is such that it is capable of transmission of
all torque encountered during its service.
• b) The coupling must not influence the smooth running of the shaft
assembly
26 May 2012 PMI Revision 00 32
26 May 2012 PMI Revision 00 33
26 May 2012 PMI Revision 00 34
26 May 2012 PMI Revision 00 35
26 May 2012 PMI Revision 00 36
26 May 2012 PMI Revision 00 37
SALIENT FEATURES OF TURBINE ERECTION
(CONT)
•After carrying out the coupling check and
performing the adjustments necessary in the shaft
position, the coupling of the shafts is carried out.
Check for concentricity / radial alignment before
carrying out the the coupling. Also measure the
clearance between the spigot & recess. This
should be well within the specified limit s of
0.08mm or else it shall give a lot of problem while
doing the alignment of the rotors. There after
carry out the axial alignment of the rotors
SALIENT FEATURES OF TURBINE ERECTION
(CONT)
•After carrying out the coupling check and
performing the adjustments necessary in the shaft
position, the coupling of the shafts is carried out.
Check for concentricity / radial alignment before
carrying out the the coupling. Also measure the
clearance between the spigot & recess. This
should be well within the specified limit s of
0.08mm or else it shall give a lot of problem while
doing the alignment of the rotors. There after
carry out the axial alignment of the rotors
26 May 2012 PMI Revision 00 38
SALIENT FEATURES OF TURBINE ERECTION
(CONT)
•While coupling ensure the concentricity of the coupling
holes of the two coupling. This shall minimize the
requirement of reaming & honing. A run out check at the
shaft journal is necessary to ensure a good coupling. It
may be noted that even a run out of 0.03mm at journal
area will eventually lead to vibrations of 30 microns.A
higher run out is an indication of improperly connected
coupling. It is imperative to locate the cause of the
improper connection& to eliminate them by appropriate
measures
SALIENT FEATURES OF TURBINE ERECTION
(CONT)
•While coupling ensure the concentricity of the coupling
holes of the two coupling. This shall minimize the
requirement of reaming & honing. A run out check at the
shaft journal is necessary to ensure a good coupling. It
may be noted that even a run out of 0.03mm at journal
area will eventually lead to vibrations of 30 microns.A
higher run out is an indication of improperly connected
coupling. It is imperative to locate the cause of the
improper connection& to eliminate them by appropriate
measures
26 May 2012 PMI Revision 00 39
SALIENT FEATURES OF TURBINE ERECTION
(CONTD..)
•CASING GUIDES: The casing guides are used to link
the turbines & bearing casing together in such away
that turbine casing can expand freely in desired
direction when heated. Prior to installation of the
turbine casing, check their mating surfaces& t6hose of
bearing casing for perfect condition. Permanent casing
guide keys are fixed with required clearance after the
final alignment of rotor and casings. Ensure a thin layer
of molykote on keys while installing. The thickness of
keys& the clearances are to be recorded in the log-
sheets
SALIENT FEATURES OF TURBINE ERECTION
(CONTD..)
•CASING GUIDES: The casing guides are used to link
the turbines & bearing casing together in such away
that turbine casing can expand freely in desired
direction when heated. Prior to installation of the
turbine casing, check their mating surfaces& t6hose of
bearing casing for perfect condition. Permanent casing
guide keys are fixed with required clearance after the
final alignment of rotor and casings. Ensure a thin layer
of molykote on keys while installing. The thickness of
keys& the clearances are to be recorded in the log-
sheets
26 May 2012 PMI Revision 00 40
26 May 2012 PMI Revision 00 41
SALIENT FEATURES OF TURBINE ERECTION
(CONTD..)
•CASING SUPPORTS :The position of all outer casing &
that of inner casing of LP turbine are fixed horizontally
by casing supports. When the turbine casing rests on
the bracket supports the casing is at proper elevation
wrt turbine shaft
•The HP &IP turbine casing are supported in the turbine
axis by two front & two rear bracket supports standing
on the support blocks of the pedestals.The support are
free to slide during the thermal expansion
SALIENT FEATURES OF TURBINE ERECTION
(CONTD..)
•CASING SUPPORTS :The position of all outer casing &
that of inner casing of LP turbine are fixed horizontally
by casing supports. When the turbine casing rests on
the bracket supports the casing is at proper elevation
wrt turbine shaft
•The HP &IP turbine casing are supported in the turbine
axis by two front & two rear bracket supports standing
on the support blocks of the pedestals.The support are
free to slide during the thermal expansion
26 May 2012 PMI Revision 00 42
26 May 2012 PMI Revision 00 43
•BEARING PEDESTALS
The Function of the Bearing Pedestal Is To:
-Support the Rotors
-Connect HP & IP to Form One Unit
-Support HP & IP Turbine Sections
-Center the Turbine Sections
•THRUST BEARING takes care of the uncompensated residual thrust
•FRONT BEARING PEDESTAL houses the main oil pump for lube oil
& control oil. The over speed trip device is also installed in this
pedestal
•AXIAL MOVEMENT : those pedestals which are not fixed point are
designed to take care of thermal expansion. The movement is based
in the length of the turbine section and the casing temperatures
• Setting of spacer bolt clearance
•Checking of radial & axial clearance on the right & left hand sides
•BEARING PEDESTALS
The Function of the Bearing Pedestal Is To:
-Support the Rotors
-Connect HP & IP to Form One Unit
-Support HP & IP Turbine Sections
-Center the Turbine Sections
•THRUST BEARING takes care of the uncompensated residual thrust
•FRONT BEARING PEDESTAL houses the main oil pump for lube oil
& control oil. The over speed trip device is also installed in this
pedestal
•AXIAL MOVEMENT : those pedestals which are not fixed point are
designed to take care of thermal expansion. The movement is based
in the length of the turbine section and the casing temperatures
• Setting of spacer bolt clearance
•Checking of radial & axial clearance on the right & left hand sides
26 May 2012 PMI Revision 00 44
The Erection any equipment is a complete & systematic
process which is well conceived before start of the job.
It involves detailed planning about the content and the
scope of work that needs to done. The complete
technical specification of the equipment, its Layout, the
foundations, and the Terminal points have to be defined
before the start of the work. It is well said, that a work
well planned is half done.
Thus while award of the work the complete technical
specifications are frozen in detail during pre award
discussions with the Engineering and the Contract
services.
The Erection any equipment is a complete & systematic
process which is well conceived before start of the job.
It involves detailed planning about the content and the
scope of work that needs to done. The complete
technical specification of the equipment, its Layout, the
foundations, and the Terminal points have to be defined
before the start of the work. It is well said, that a work
well planned is half done.
Thus while award of the work the complete technical
specifications are frozen in detail during pre award
discussions with the Engineering and the Contract
services.
26 May 2012 PMI Revision 00 45
-The complete erection of a TG is a long drawn process
requiring more that 30 months of work.
-Thus the sequence of supplies and their dates of
dispatches are decided before hand.
-Similarly the dates of readiness of the Foundations is also
decided before hand.
-The Terminal points are also decided before the Final
award of the contract i.e. NTPC scope(Customer Scope)
which generally are free construction power supply, water
supply, Civil foundations, EOT Crane (optional) with
operators, Compressed air, Area lighting, accommodation
land, storage area, DM water etc.
-The rest of the work is in the scope of the equipment
supplier.
- This includes Supply, Storage, Erection, Testing &
Commissioning and Trial operation of the equipment.
-The complete erection of a TG is a long drawn process
requiring more that 30 months of work.
-Thus the sequence of supplies and their dates of
dispatches are decided before hand.
-Similarly the dates of readiness of the Foundations is also
decided before hand.
-The Terminal points are also decided before the Final
award of the contract i.e. NTPC scope(Customer Scope)
which generally are free construction power supply, water
supply, Civil foundations, EOT Crane (optional) with
operators, Compressed air, Area lighting, accommodation
land, storage area, DM water etc.
-The rest of the work is in the scope of the equipment
supplier.
- This includes Supply, Storage, Erection, Testing &
Commissioning and Trial operation of the equipment.
26 May 2012 PMI Revision 00 46
Pert Networks
•The contractor is required to submit a PERT
network indication the major mile stone dates
•The three types viz. L1, L2 & L3 networks are
submitted by the contractor which is
reviewed & finalized after incorporating the
comments of the owner. L3 is the complete
detailed network which is normally used at
site for each commitment
•Similarly the supplies are also decided as per
the milestone dates and any slippage from
the committed date is subject to LD to be
levied by the owner. This is levied @ 1/2 %
per week’s delay subject a maximum ceiling
of 5 %
Pert Networks
•The contractor is required to submit a PERT
network indication the major mile stone dates
•The three types viz. L1, L2 & L3 networks are
submitted by the contractor which is
reviewed & finalized after incorporating the
comments of the owner. L3 is the complete
detailed network which is normally used at
site for each commitment
•Similarly the supplies are also decided as per
the milestone dates and any slippage from
the committed date is subject to LD to be
levied by the owner. This is levied @ 1/2 %
per week’s delay subject a maximum ceiling
of 5 %
26 May 2012 PMI Revision 00 47
Handing Over Of Fronts
• The fronts are handed over to the contractor after due
checking of the soundness & dimensional check of the elevation
& pocket, insert sizes and their location after a joint protocol
•It is essential to provide weather proof TG hall along with crane
girder which includes side wall cladding, railway siding,
approach ladders / staircase, adjoining floors etc
Handing Over Of Fronts
• The fronts are handed over to the contractor after due
checking of the soundness & dimensional check of the elevation
& pocket, insert sizes and their location after a joint protocol
•It is essential to provide weather proof TG hall along with crane
girder which includes side wall cladding, railway siding,
approach ladders / staircase, adjoining floors etc
26 May 2012 PMI Revision 00 48
CONSTRUCTION OF TG DECK
•The TG deck is supported on steel / RCC
columns. A vibration isolation system is
provided on the column to isolate the deck
vibrations from the columns
•After the layout of steel inserts on the form
work/ shuttering, the TG deck is constructed
by a process of non stop casting in order to
provide monolithic structure. The cement
setting is delayed by adding certain additives
to the concrete mixture. The curing is carried
out for a period of 28 days after which it is
released for erection of the equipments
CONSTRUCTION OF TG DECK
•The TG deck is supported on steel / RCC
columns. A vibration isolation system is
provided on the column to isolate the deck
vibrations from the columns
•After the layout of steel inserts on the form
work/ shuttering, the TG deck is constructed
by a process of non stop casting in order to
provide monolithic structure. The cement
setting is delayed by adding certain additives
to the concrete mixture. The curing is carried
out for a period of 28 days after which it is
released for erection of the equipments
26 May 2012 PMI Revision 00 49
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THANK YOU
THANK YOU
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