POWER SYSTEMS

MODIFICATIONS TABLE

REV PREPARED CHECKED APPROVED DATE MODIFICATIONS STAT.

A M.SUBRAMANIAN HARSH GHOGARE VINOD SANATOO 4th SEPTEMBER 2014 FIRST ISSUE GFE

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INDEX

ERECTION OF TURBINE MECHANICAL PARTS

1. PURPOSE

2. SCOPE

3. SAFETY PRECAUTION

4. PREPRATION

ERECTION PROCEDURE

5. ERECTION OF DRAFT TUBE CONE & BOTTOM RING

6. ERECTION OF RUNNER

7. TRAIL ASSEMBLY OF HEAD COVER, SHAFT SEALSUPPORT & GUIDE BEARING SUPPORT

8. ERECTION OF WICKET GATE, HEAD COVER, OPERATING RING

9. ERECTION OF TURBINE SHAFT

10. FINAL ASSEMBLY OF WICKET GATE, OPERATING RING AND ITS MECHANISMS

11. ERECTION OF SHAFT SEAL

12. ERECTION OF TURBINE GUIDE BEARING

13. ERECTION OF WICKET GATE SERVOMOTOR

14. ERECTION OF AIR ADMMISION VALVES

15. ERECTION OF TURBINE & GENERATOR COUPLING

16. REFERENCE DOCUMENTS

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1. PURPOSE

The propose of this document is to define general erection guide lines to be followed at site by Erection
team, General assembly drawings are the final reference for installation.

Note: This Erection Procedure can be changed by Erection Supervisor at site based on site condition.

2. SCOPE

• This document is applicable for HULU TERENGGANU HYDROELECTRIC PROJECT only.

3. SAFETY PRECAUTION

• Prior to start of erection works, ensure following for safety:

To be ensured by Client :

1. Trouble free access to the working fronts.

2. Ensure that all the required reinforcement bars are bended.

3. No activities are going above working fronts to avoid any object falling.

4. No activities should be taken under working fronts to avoid any miss-happening.

5. Working fronts should be dry and clean.

6. Removal of all Exposed cables if any around working fronts.

7. All the gas cylinders opening are properly tight and chained to avoid any fire.

8. All the loose material on roof to be removed prior start of erection.

9. Advance information to be given in case of any blast.

10. Pollution to be controlled as per Indian / Alstom standard.

11. Dangerous area to be marked properly.

12. Opening / Block out to be plugged and fenced.

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• Alstom will also ensure above applicable safety precaution in their working area during execution.

4. PREPARATION

Client to ensure all bench marks. Unit axis (X & Y) and Elevation.
Alstom to ensure that all bench marks are punched on properly fixed plates to avoid any
Misalignment during the course of execution.

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ERECTION PROCEDURE

5. ERECTION OF DRAFT TUBE CONE & BOTTOM RING

Sketch No: - 1.0

Refer IS No : 1,2,3,4,5,6,7,8,9 & 15

- After completion of 4th Stage concrete (Spiral Case and upper Pit liner) remove all bracing from upper and
lower pit liner.

- Dismantling of Dummy distributor from stay ring and keep it on service bay to use for second unit spiral
case testing.

- Cleaning of Stay ring upper and lower flanges.

- Check Stay ring horizontality and radius after concreting.

- If necessary, perform grinding on Stay ring ID to achieve the required radius dimension, in consents with
engineering.

- Measurement of height between DT top and Stay Ring to determine the cutting of extra length of DT.

- Perform cutting/grinding of DT extra length.

- Lower the DT cone on Draft Tube top.

- Transport the Bottom Ring to Service Bay.

- Cleaning of Bottom Ring at Service Bay.

- Installation of Bottom Ring handling device.

- At pit - installation of wedging washer on Stay Ring bottom flange and determine the thickness of washer
, machining of washer as required for adjusting horizontality and elevation of Bottom ring, and tack
welding of wedging washer on Stay Ring .

- Check horizontality at washer along with before & after machining of washer.

- Check the thickness of Wedging Washer.

- Lowering of Bottom Ring on Wedging washer.

- Align the bottom ring w.r.t Unit Centre Line and elevation.

- Clamping of Bottom Ring with Stay Ring.

- Check Bottom Ring alignment .

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- Install the fixing bolts between Cone and bottom ring and lift the cone and clamp with Bottom Ring .

- Check the alignment of DT cone w.r.t Centre Line & Bottom Ring.

- Tightening of DT Cone with Bottom Ring.

- Fixing of weld clamp on DT cone and DT, and welding with DT and DT Cone.

- Fixing of back plate , welding with DT cone and apply Silicon on DT side.

- Install turnbuckles, and tight it.

- Install anchor rod.

- Install Water ring relief pipe DN 200, Pressure tap piping .

- Release the DT cone for 5th stage concrete.

After Concreting of DT Cone:

- Remove Bracing inside DT Cone, remove Exposed turn buckles.

- Check bottom ring position after DT Cone Concreting.

- Perform welding between DT and cone. (Inside)

- Check Bottom Ring Position after DT Cone welding.

- Dismantle Bottom Ring from DT Cone. (Before dismantling of Bottom ring, drill and ream with Stay Ring
and DT Cone.

- Installation “O” rings on DT Cone Flange.

- Lowering of Bottom Ring on Stay Ring and clamping with Stay Ring.

- Tight DT Cone with Bottom Ring.

- Check the alignment of Bottom Ring w.r.t centre Line & Elevation.

- Perform grinding on DT cone and DT weld for smooth hydraulic path.

- Install “O” ring between Stay Ring and Bottom Ring with seal retaining plate and clamping.

- Fill Belzona N*1111 inside clamping ring holding bolts and cleaning to maintain hydraulic profile.

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6. ERECTION OF RUNNER

Sketch No: - 2.0

Refer IS No : 20,21 & 23

- Install runner erection platform at DT Cone. ( H 6745 00 MEF 80 02 LD)

- Prepare 08 nos. of wedge for runner erection on DT cone. (Will keep Runner elevation -25mm from design
elevation)

- Transport Runner to Service bay and cleaning.

- Install lifting arrangement as per drg. No. (H6745 00 MEF 80 01LD)

- Lower Runner on temporary wedges installed on DT Cone.

- Keep mark R-R on Runner coupling flange at upstream side.

- Leveling and centering of Runner with bottom Ring.

- Check horizontality of coupling flange and lower wearing gap.

- Locking of Runner at DT Cone.

- After run out check install runner cone to runner.

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7. TRAIL ASSEMBLY OF HEAD COVER, SHAFT SEALSUPPORT & GUIDE BEARING SUPPORT

Sketch No: - 3.1 , 3.2 & 3.3

Refer IS No : 10,11,12,13,14,17,& 22

- At pit - installation of wedging washer on Stay Ring Top flange and determine the thickness of washer ,
machining of washer as required for adjusting horizontality and elevation of Head Cover, and tack welding
of wedging washer on Stay Ring .

- Check horizontality at washer along with before & after machining of washer.

- Check the thickness of Wedging Washer.

- Transport Head cover to Service Bay and cleaning.

- Installation of four wicket gate with lower housing on Bottom Ring.

- Lower Head Cover on Stay Ring and alignment of Head Cover with Bottom ring and runner.

- Check Head Cover Alignment

a) Horizontality at Guide Bearing Support flange.

b) Gap between Runner and upper wearing Ring.

c) Distributor Height.

d) Gap Between Upper Face Plate & Wicket Gate upper face.

e) Gap between head Cover and Stay Ring ID.

- Doweling/ Pinning of Head Cover with Stay Ring.

- At service Bay - assembly Inflatable seal support, clamp and seal.

- Lowering of Inflatable Seal Support on Head Cover Flange, Centering and pining with head cover.

- Lowering of Guide Bearing Support on Head Cover flange, Centering and Provisional Pinning with Head
Cover.

- After trial Assembly dismantled Guide Bearing Support, Inflatable Seal Support and Head Cover.

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8. ERECTION OF WICKET GATE, HEAD COVER, OPERATING RING

Sketch No: - 4.0

Refer IS No : 12,16,18,46 & 47

- Install seal , Bronze seal Sector and inner and outer seal clamp to Bottom Ring and Head Cover.

- Installation of Lower Housing and its accessories to the Bottom Ring.

- Lowering all wicket gate on bottom Ring with “U” seal and “O” ring and keep the wicket gates in Closed
position.

- Lowering of Head Cover on Stay Ring upper flange. ( Close/protect all opening on Head Cover to prevent
falling of any material between Runner and Head Cover.)

- Clamping of Head Cover with Stay Ring as per torque.

- Check Head Cover Alignment

a) Horizontality at Guide Bearing Support flange.

b) Gap between Runner and upper wearing Ring.

c) Distributor Height.

d) Gap Between Upper Face Plate & Wicket Gate upper face.

e) Gap between head Cover and Stay Ring ID.

- Install “O” ring between Stay Ring and Head Cover with seal retaining plate and clamping

- Fill Belzona N*1111 inside clamping ring holding bolts and cleaning to maintain hydraulic profile

- Installed all upper Housing on Head Cover clamp with head cover with screw and dowel pin.

- Lowering of regulating Ring on head Cover.

- Centering/ clamping of regulating ring with head Cover, check the clearance at vertical and horizontal
sectors.

Note: Operating Ring Mechanism components at turbine pit before Shaft Free.

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9. ERECTION OF TURBINE SHAFT

Sketch No: - 5.0

Refer IS No : 26 & 41

At Service Bay:

- Transport Shaft from store to Service Bay.

- Cleaning of Shaft.

- Installed handling device as per drawing and put Shaft in vertical position.(H-6745 00 MEF 80006LD)

- Assembly of guide bearing oil pot around shaft and Seal welding/ NDT.

AT Pit:

- Install “O” ring on Runner.

- Lowering Turbine Shaft on Runner for coupling. (respect R-R mark on flange before coupling)

- Installed coupling pins and secure with locking plate.

- Install coupling Stud and nut and torque.

- Locking of coupling stud and Nut by locking bar and weld.

- Check Horizontality , verticality and Elevation of Shaft.

- Install centering reference point on pit liner and TGB support.

Note: Transfer the Centre line & shaft Elevation on Pit Liner and record for reference.

- Locking of Runner at Lower Wearing ring.

- Lower and keep secure all turbine heavy components on head cover.

- Turbine Shaft free for Generator erection.

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10. FINAL ASSEMBLY OF WICKET GATE, OPERATING RING AND ITS MECHANISMS

Sketch No: - 6.0

Refer IS No : 24,25,42,43,44 & 45

After Shaft free continue with Wicket Gate assembly

- Lowering of assembly of Wicket Gate Lever and thrust washer on upper housing.

- Installation of Conical pin between Wicket Gate and lever.

- Installation of Wicket Gate handle on Wicket Gate lever , install breaking pin and clamp with special
stud.

- Installation of Wicket Gate Cover on WICKET GATE Lever.

- Adjust the Wicket Gate clearance by adjusting screw at top and Bottom.

- Check Wicket Gate clearance at Bottom Ring and Head Cover.

- Installation of Dome Nut and Screw.

- Installation of counter thrust ring with strippable shims and adjust the Gap with thrust washer and clamp
with upper housing.

- Check the gap between counter thrust ring and thrust washer.

- Close all Wicket Gate and fixed with rope and pull -lift.

- Keep Regulating ring in closed position.

- Installation of Link between Wicket Gate handle and regulating ring with offset pin and link pin .

- Remove rope and pull – lift around Wicket Gate.

- Check Wicket Gate clearance at closed position.

- Lock all pins by screw .

- Lock all bolts by welding strip.

- Perform Pre-stressing of Distributor with Wicket Gate servomotor.

- Installation of limit switch on Wicket Gate.

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11. ERECTION OF SHAFT SEAL

Sketch No: - 7.0

Refer IS No : 19,27,28,29,30,31 & 32

Shaft Seal Assembly before Shaft free:

- Installed wearing plate on Shaft and Secure with bolt as per torque.

- Check horizontality of wearing plate.

- Lower inflatable seal support assembly on Head Cover and clamp with Head Cover.

- Check the radial Gap between seal holder and wearing ring.

- Check the leakage test on Inflatable seal.

- Lower “U” seal on keep secure on wearing ring.

- Lower all Shaft Seal component and keep secure at Head Cover.

Shaft Seal Assembly after Turbine and Generator Coupling:

- Lower and assembly of Movable Ring on wearing ring.

- Assembly of Sealing ring with movable Ring. ( Don’t forget copper implant and pin to assemble)

- Check the holes provided for RTD on movable ring.

- Lower and assemble Fixed Support on Inflatable seal support. ( Install “U” seal and “O” ring )

- Check the radial clearance between support and movable ring.

- Doweling of fixed support and Inflatable seal support, install dowel .

- Assemble two thrust block in diametrical opposite position on movable ring and drill and rim with
movable ring .

- Assemble all thrust block on movable ring with deflector and ensure clearance between tensile rod and
clamp with movable ring.

- Assemble Springs , Special Washer and Screw and set the Spring height.

- Installation of Shaft seal wearing indicator rod.

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- Installation of Shaft seal Cooling water coupling on movable ring as per Drawing no. H6745 00 MEF 70
07LD.

- Installation of pressure taping connector and pipe as per drawing no. H6745 00 MEF 70 14 LD.

- Plug on fixed support.

- Lowering / assembly / installation of tank with inflatable seal support.

- Install cooling water hose pipe from movable ring to tank.

- Install RTD from movable ring to Tank. As per drg. H674500 MEF 48 001 LD.

- Assemble and Installation of Shaft deflector on Turbine Shaft.

- Assembly and installation of Tank cover

- Installation of cover.

- Install wearing ring indicator.

- Install all instrumentation as per drg. H674500 MEF 48 001 LD.

- Installation of inflatable Seal air piping

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12. ERECTION OF TURBINE GUIDE BEARING

Sketch No: - 8.0

Refer IS No : 33,34,35,36,37,38,39 & 40

Turbine Guide Bearing assembly Before Shaft free:

- Lower and installed Turbine Guide Bearing support on Head Cover.

- Centering of TGB support with Shaft. (put in place provisional dowel pin )

- Clamping of TGB support.

Turbine Guide Bearing Assembly after Turbine and Generator coupling & Run out

- Lift the oil pot and secure with Shaft before start Shaft Seal assembly.

- Install Guide Pad Support on TGB support and clamp with TGB support.

- Assemble Bottom Cover .

- Install “O” ring on Bottom Cover.

- Lower and Assemble oil pot with Bottom cover and clamp with bolt .

- Install “O” ring on Bottom Cover and lift the complete assembly and clamp with TGB bottom with bolts.

- Install Guide Bearing pads on pad support, Guide pad pins , hex bolt, threaded cylinder, wedge locking
plate, nut & Taper wedge .

- Adjust gap with taper wedge on all 08 nos. of pad by adjusting taper wedge.

- Check the radial clearance between guide pads.

- Installation of locking plate , check the Gap.

- Installation of Instrumentation as per drawing no. H 6745 00 MEF 40 003 LD. (RTD, Level Indicator,
moisture detector etc)

- Check the assembly of hose pipe of cooling oil.

- Assembly of sealing cover with lower diaphragm , centering, clamping and doweling with TGB support.

- Check radial clearance between shaft and lower diaphragm.

- Assembly of cooling oil hose pipe with ‘O” ring and locking with lock plate.

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- Assembly of upper bearing cover with upper diaphragm , centering, clamping and doweling with TGB
support.

- Check the radial clearance between upper diaphragm and Shaft.

- Install plug on bottom cover.

- Installation of sight glass support and Sight glass on bearing cover.

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13. ERECTION OF WICKET GATE SERVOMOTOR

Sketch No: - 9
Refer IS No : 48,49,50,51,52,53,54 & 55

At Pit (Before Shaft free)

- Torque servomotor base plate Stud.

- Installation in the recesses of the handling tool of Servomotor as per drawing No. H6745 00 MEF 80
016LD

- Lower and installed Servomotors without Adjusting washer to the base plate. (Use soft wedge)

- After Wicket Gate/ Operating Ring / alignment

- Alignment of Servomotors . ( Offering –up the servomotor in respect to distributor in closed position)

- Check alignment.

- Determine the thickness of adjustment plate, Machining of adjustment washer.

- Dismantled Servomotor, install adjustable washer after machining, re- install Servomotor and Clamp
with Base plate.

- Check alignment of Servomotor.

- Connect the Servomotor to regulating ring.

- The prestressing of the distributor and the control of good working of lock will be carried out during test.

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14. ERECTION OF AIR ADMMISION VALVES

Sketch No: - 10.0

Refer IS No : 63

- Installation of “O” ring on Generator Shaft.

- Installation of Pipe -1 on top Generator Shaft and clamp with screw.

- Before Generator top Shaft Lowering, installation of Central Pipe with “O” ring and clamp, drill /rim for
dowel.

- Installation of Support on Collector Ring Supporting Disc.

- Installation of Sleeve with O ring , dowel and clamp.

- Installation of Valve Box .

- Installation of air admission valve assembly.

- Check Gap between valve cover and valve box.

- Drilling and Rimming of valve box and collector ring cover.

- Check oil level inside valve piston.

- Installation of Cover assembly.

- Installation of Piping.

- Installation of Instrumentation.

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15. ERECTION OF TURBINE & GENERATOR COUPLING

Sketch No: - 11.0

Refer IS No : 56,57,58,59,60,61 & 62

- Installation of “O” ring on turbine Shaft.

- Match R-R marking with the Turbine and Generator Shaft.

- Check Parallelism and concentricity between both the Shaft.

- Installation of all coupling Stud and Nut to Shafts.

- Installation of hydraulic tensioner on stud.

- Couple Turbine and Generator.

- Prestressing of Coupling stud.

- Lock the Stud mechanically.

- After Shaft Seal and Guide bearing Box-up

a) Clearance between upper and Lower wearing ring.

b) Centering at TGB.

c) Centering at Shaft Seal.

d) Clearance between upper & Lower Laybrinth

- Check Run out Inspection.

- Start box-up of TGB and Shaft Seal.

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16. REFERENCE DOCUMENTS

Control sheets

- H-6745 00 MEF 00 081 BB

Field Quality Control Plan

- H-6745 01 MEF 00 001 QA

Reference Drawing

- H-6745 00 MEF 00 001 TL

- H-6745 00 MEF 20 001 LD

- H-6745 00 MEF 30 001 LD

- H-6745 00 MEF 30 002 LD

- H-6745 00 MEF 30 003 LD

- H-6745 00 MEF 40 001 LD

- H-6745 00 MEF 40 002 LD

- H-6745 00 MEF 00 001 LD

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