1. The document discusses issues with a spring-loaded turbine generator (TG) deck foundation at the Simhadri 2x500 MW power station, including changing catenary readings as load was added to the deck.
2. Measurements showed some spring assemblies were loaded beyond expected design loads. This caused the elevation of the deck to change frequently, complicating machine erection.
3. Recommendations included unlocking and adjusting all deck springs to stabilize the elevation, and improving protocols for measuring and recording spring properties during installation.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online from Scribd
1. The document discusses issues with a spring-loaded turbine generator (TG) deck foundation at the Simhadri 2x500 MW power station, including changing catenary readings as load was added to the deck.
2. Measurements showed some spring assemblies were loaded beyond expected design loads. This caused the elevation of the deck to change frequently, complicating machine erection.
3. Recommendations included unlocking and adjusting all deck springs to stabilize the elevation, and improving protocols for measuring and recording spring properties during installation.
1. The document discusses issues with a spring-loaded turbine generator (TG) deck foundation at the Simhadri 2x500 MW power station, including changing catenary readings as load was added to the deck.
2. Measurements showed some spring assemblies were loaded beyond expected design loads. This caused the elevation of the deck to change frequently, complicating machine erection.
3. Recommendations included unlocking and adjusting all deck springs to stabilize the elevation, and improving protocols for measuring and recording spring properties during installation.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online from Scribd
1. The document discusses issues with a spring-loaded turbine generator (TG) deck foundation at the Simhadri 2x500 MW power station, including changing catenary readings as load was added to the deck.
2. Measurements showed some spring assemblies were loaded beyond expected design loads. This caused the elevation of the deck to change frequently, complicating machine erection.
3. Recommendations included unlocking and adjusting all deck springs to stabilize the elevation, and improving protocols for measuring and recording spring properties during installation.
Copyright:
Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online from Scribd
Download as ppt, pdf, or txt
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SPRING LOADED TG DECK FOUNDATION
FOLLOWING SLIDES SHOW THE PROCEDURE OF INSTALLING THE SPRING ASSEMBLIES IN A SPRING LOADED TG DECK FOUNDATION :
CHANGE OF CATENARY READINGS SIMHADRI 2X500 MW
FOLLOWING HAS BEEN REPORTED FROM THE ABOVE POWER STATION: CHANGE IN CATENARY READING OF SIMHADRI 1 AFTER FLOATING OF TG DECK. CHANGE IN CATENARY READINGS (BEARING PEDESTAL HEIGHTS) AT SIMHADRI UNIT-2 WITH FOLLOWING CONDITIONS: - CONDENSER NECK NOT WELDED TO TURBINE. - COMPLETE WEIGHT OF MACHINE NOT YET ERECTED ON TG DECK. - TIE ROD BOLTS OF FEW SPRING ASSEMBLIES FOUND LOOSE, OTHERS COULD NOT PROBLEMS. SITE WAS ADVISED TO MAKE FOLLOWING MEASUREMENTS: - BETWEEN TG DECK AND COLUMN TOP. - BETWEEN SPRING ASSEMBLIES (REFER THE ENCLOSED SKETCH). DATA HAS BEEN RECEIVED FROM SITE INDICATING MAJORITY OF SPRING ASSEMBLIES HAVING BEING LOADED BEYOND THE EXPECTED DESIGN LOAD. BE CHECKED DUE TO ACCESSIBILITY
CHANGE OF CATENARY READINGS SIMHADRI 2X500 MW
THE ABOVE FACTS PROVE THAT ELEVATION OF THE DECK KEEPS CHANGING WITH ADDITION OF LOAD ON TG DECK EVEN PRIOR TO UNLOCKING OF SPRING ASSEMBLIES. ERECTION ENGINEERS AT
SIMHADRI SITE ARE FINDING IT DIFFICULT TO FINALISE THE
REFERENCE FOR CENTERING OF CYLINDER, ALIGNMENT AND CATENARY OF THE MACHINE. MOVING DECK HAS RESULTED IN FREQUENT CHECKING OF CENTERING AND ALIGNMENT READINGS. THIS HAS RESULTED IN INCREASE OF ERECTION TIME.
CONCLUSIONS FROM THE READINGS TAKEN AT SIMHADRI, ANY ONE OF THE FOLLOWING MAY BE TRUE: 1. ERROR IN COMPUTING THE DESIGN LOAD OF TG DECK ALONGWITH EQUIPMENT. 2. INADEQUATE STIFFNESS OF SPRINGS.
ACTION PLAN FOR SIMHADRI-2
REFER TO ERECTION PROTOCOLS. READINGS SET DURING
PLACEMENTS OF SPRING ASSEMBLIES BEFORE CASTING OF TG DECK.
NO NECK WELDING OF CONDENSER TO TURBINE TO BE DONE.
IF TAG WELDED, REMOVE THESE.
UNLOCK ALL TG DECK SPRINGS ASSEMBLIES AND FLOAT THE TG DECK. CONDUCT NECESSARY SHIMMING TO ACHIEVE THE ELEVATION
AND CATENARY OF THE MACHINE.
LOCK ALL TG DECK SPRING ASSEMBLIES WITH SUFFICIENT MARGIN FOR FURTHER LOADING OF TG DECK. WHILE DOING THIS ACTIVITY, REFER TO BENCH MARK AND BEARING PEDESTAL ELEVATION READING TAKEN BY TURBINE ERECTION RECORD READINGS. GERB TO PROVE THE HEALTHINESS OF SPRING ASSEMBLIES SUPPLIED FOR SIMHADRI.
ISSUES SITE FEEDBACK INDICATES INCREASE IN ERECTION CYCLE TIME. NO FLEXIBILITY IN SEQUENCE OF ERECTION ACTIVITIES. NO APPRECIABLE GAIN IN VIBRATION LEVEL ON MACHINE WITH SPRING LOADED TG DECK. INCREASE IN OVERHAULING TIME OF TURBINES WITH
SPRING LOADED TG DECK. PROTECTION FROM SEISMIC LOADS. PRECAUTION FROM SEISMIC LOADS NOTED. GE / ALSTOM MAKE TURBINES DO NOT ENCOURAGE USE OF SPRING LOADED TG DECK.
WHAT SHOULD BE BHELS STRATEGY FOR FUTURE SETS ?
ACTION PLAN FOR FUTURE SETS:
TASK DURING ERECTION ELEVATION OF TG DECK SHOULD NOT CHANGE
WITH CHANGE OF LOAD IN TG DECK. TO ACHIEVE THIS WE PROPOSE:
GERB SHOULD PROVIDE BOTH SIDE LOCKING IN SPRING ASSEMBLIES AS IN CONDENSER SPRING ASSEMBLIES. GERB TO RECONSIDER THE AMOUNT OF ADDITIONAL PRESTRESSING. FOLLOWING ADDITIONAL PROTOCOLS NEEDS TO GENERATED WHILE PRE-STRESSING THE SPRINGS AT SITE FOLLOWING MEASUREMENTS TO BE NOTED: GAP BETWEEN SPRING ASSEMBLY WITH TIE BOLTS LOOSE (FREE LENGTH OF SPRINGS) AT FOUR LOCATIONS. FORCE REQUIRED TO PRE-STRESS TO THE DESIRED VALUE TO COMPUTE SPRING INDEX AND COMPARE WITH DESIGN VALUE FOR EACH SPRING ASSEMBLY.
ACTION PLAN FOR FUTURE SETS:
RANDOMLY SELECT FEW SUCH PRESTESS SPRING ASSEMBLIES, LOOSENING ITS TIE ROD. MEASUREMENT FREE LENGTH AND CAMPARE WITH FREE LENGTH REFERENCE COMPRESSION. ALL READINGS AS DEPICTED IN THE SKETCH TO BE TAKEN WITH INSIDE MICROMETER, LOCATION OF THE READING TO
BE DEFINED, IDENTIFIED AND PUNCHED (USE METAL
MARKER, WHERE PUNCHING CANNOT BE CARRIED OUT). LOCATION OF MEASUREMENT A SHOULD BE CHIPPED AND SMOOTHENED TO AVOID ANY DISTURBANCES DUE TO LOOSE CONCRETE. BEFORE FLOATING OF TG DECK PUT FOUR DIAL GAUGE INDICATORS ON TOP OF TG DECK. SET IT ZERO W.R.T. TG FLOOR. CHECK AND RECORD THE READINGS AFTER FLOATING OF TG DECK.
ACTION PLAN FOR FUTURE SETS:
VENDOR TO GIVE INSTALLATION MANUAL TO PROVIDE A STEPWISE INSTRUCTIONS AND NUMBER OF PROTOCOLS TO BE GENERATED. BHEL TURBINE ERECTION ENGINEER TO INVOLVE DURING THE COMPLETE INSTALLATION OF DECK SPRINGS.
SCHEMATIC FOR GERB SPRING
TG DECK
SHIM TIE ROD
TG COLUMN
NOTE: 1. THESE READINGS ARE IN ADDITION TO READING TAKEN BY GERB ON THE PROTOCOL DOCUMENT. 2 TURBINE ENGINEER ALONG WITH CIVIL ENGINEER TO ASSOCIATE.
A.
B. C
STICK MICRO METER READING AT FOUR LOCATIONS BETWEEN DECK AND COLUMN. MARK THE LOCATION OF READING (USE METAL MARKER). STICK MICROMETER READING AT FOUR LOCATION OF EACH SPRING ASSEMBLY. RECORD TOTAL THICKNESS OF SHIM HEIGHT AND NUMBER OF SHIMS.
