erectionofvariousmajorequipmentsinpowerproject128201141213pm

8/3/2019 Erectionofvariousmajorequipmentsinpowerproject128201141213PM

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Condenser Sequential Erection Process:

1. Marking of center axis both X & Y (Longitudinal & Transverse).2. Hot well assembly / pre assembled plates are to be kept in position.3. Cleaning of foundation, chipping, packer plates fixing, leveling & grouting of packer

plates.

4. Positioning, Leveling of springs & locking the same.5. Erection of condenser saddle supports on the spring.6. Erection of condenser pre assembled bottom plate.7. Erection of side walls of condenser.8. Erection & alignment of front & rear tube plates.9. Fixing & alignment of intermediate tube support plates.10.Final alignment of all the support plates & leveling of condenser.11.Locking of all the plates rigidly.12.Welding of support plates as per the specification & as per welding sequential procedure.13.Erection Alignment & welding of steam spacer chamber & its supporting Structure.14.Erection Alignment & welding of air evacuation piping plates of condenser.15.Cover the top of condenser (for entry of any foreign materials that can damage the tubes).16.Cleaning of all the tube holes of each supporting plate free from burr before starting of

insertion of tubes.

17.Leveling, Tubes Expansion, excess tube cutting if required & beveling as per proceduregiven.

18.Erection of water box covers with proper positioning of Gasket/ O-ring.19.Uniform & sequent ional tightening of bolts for equal compression of gasket/ o-ring.20.

Erection, alignment of & welding of hot well.

21.Arrangements for leak testing of steam space by dummying the tapping points where everrequired.

22.Fill DM water into the condenser up to steam space of condenser.23.Mixing of fluorescent chemical in water check the tube from outside with UV lamp for any

leaks at both sides.

24.Mark the same & rectify the same.25.Leave the same for 24 hours & once again check the tube from both side for leaks.26.Drain the water to sump & allow the steam space to dry.27.Close the water boxes doors,28.Fixing of dummies for cooling water I/L & O/L connections of condenser.29.Sequential tightening of water boxes doors.30. Fill water in water boxes and raise pressure up to 1.5 times of maximum working pressure

wait for 30 minutes & check fro any leaks from door bolts.

31.Connect I/L & O/L of Cooling water ducting connections so that no load comes on tocondenser (Final joints should be free & equal gap of 3-4mm to be maintained before

welding of final joint).

32.Full Grouting of condenser.


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Turbine Oil Flushing Procedure:

1. Erection of Main Oil Tank.2. Erection of Oil Pumps, (MOP, EOP, JOP, DC EOP).3. Erection of Oil coolers, Duplex filters, Oil centrifuge, Over head oil tank.4. Erection & welding of suction piping to pumps,5. Erection of main lub. Oil inlet header.6. Erection of Lub. Oil drain header.7. Erection & welding of lub. Oil piping.8. Erection & welding of over head oil tank I/L & O/L piping.9. Erection & welding of lub. Oil connection piping to oil coolers, duplex filters piping,

coolers by-pass line for temperature control during initial start up.

10.Welding of all piping joints only by argon welding.11.Replacement of oil gaskets & check for tightness of all flange joints.12.Connect I/L & O/L oil headers through temporary piping.13.Temporary basket filter of 200micron to be erected in the O/L header near MOT area for

collection of dust & by pass valve arrangement for draining of oil in Emergency.

14.Acid pickling of all pipe lines & cleaning the same with soap solution for removing thetraces of acid on piping inner surface.

15.Clean the tank & fill the tank with flushing oil.16.Erection & commissioning of vapor Exhaust fans.17.Fix 80 micron mesh in suction strainer.18.Check the entire system as per P & I diagram for all tapping points for C & I, vent & drains.19.

Remove the oil filters & load flushing oil filters in duplex filters.20.Check for bearing oil level in pumps & commissioning the pumps one by one.

21.Staring of oil flushing & check for any leaks at the flange joints & monitor for any choke atbasket filter area and monitor the same continuously.

22.Arrange for thermal shocks by raise the temperature of the oil to 65-70 degrees by externalmeans of heating and cool the oil by charging oil cooler to 35 degrees and tap the pipe for

removing of scales.

23.Changer over of both the cooler & duplex filters has to be carried out during flushing24.Stop the pump & remove the dust collected in the basket filter & at inlet suction strainer

initially for each hour & twice a day in the later stages.

25.Change the size of the filter mesh from 200micron to 100/80 micron and continue the oilflushing.

26.Mean while all the other piping connections connected to pedestals & its loop lines forflushing the same made ready & charge the branch lines.

27.Flush the same with different sizes of basket filter mesh28.After getting clean basket filter mesh Keep 40micron mesh at the I/L of bearing & flush the

same if mesh is clear terminate the oil flushing.

29.The same procedure to be followed for TDBFP, Seal Oil piping also.


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30.After termination of oil flushing drain the oil from MOT, Oil coolers, Duplex filters, &from Suction & discharge piping.

31.Clean the MOT, over head oil tank, duplex filters free from dust & other metal particles.32.Fill fresh oil in the tank.33.Normalize the piping connections to bearings & keep 40 micron mesh at I/L of bearing

connection for all bearings.

34.Start the pump and run for 8 hours check the clear mesh.


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Turbine Erection Procedure

1. Marking of X & Y (Transverse & longitudinal axis) planes & transferring of reference benchmark level on to TG floor for each cylinder.

2. Elevation inspection & reference elevation bench mark to be transferred to TG floor.3. Chipping of TG foundation & removing of all the loose materials.4. Blue matching of all the packer plates for 80% of contact area.5. Blue matching of anchoring bolt plate to TG deck.6. Fixing & leveling of packer plates.7. Grouting of packer plates area only after leveling.8. Erection leveling & blue matching of all the pedestal base plates with packer plates.9. Erection & leveling of pedestals.10.Blue matching of pedestal base to base plate (80%) of contact area.11.Fixing & centering of pedestals.12.Fixing of keyways (axial &radial) of pedestal,13.Positioning of HP module lower half leveling & alignment of the same.14.Positioning of HP module diaphragms, alignment & centering the same with respect to

casing.

15.Positioning of HP/IP rotor.16.Rotor to diaphragms axial, radial clearances setting.17.Flow path readings check up & setting of the same if required.18.Positioning of top diaphragms, HP, IP inner casing, HP/IP outer casing and alignment of

the same check for any fouling/ mismatching.

19.Dismantling of top & inner casings of HP & IP casings20.Dismantling of all the diaphragms cleaning and assemble back for final box-up.21.Rotor positioning, clearance checking, top diaphragms (HP/IP) fixing, locking of nuts.22.HP inner casing positioning, I/P inner casing positioning.23.Sequential tightening of casing bolts HP/IP.24.Horn drop checking of each pedestal for load distribution.25.Roll checking for fixing of top, bottom & for side clearances.26.Centering of HP module w.r.t turbine axis.27.Fixing of final axial & radial keys front & rear for HP module.28.

Fixing of seal boxes (front & rear) Top & bottom & alignment of the same.

29.Bearings box-up by setting of TOP, SOP clearances.30.Boxing up of pedestals & setting of front & rear oil seals.31.Same procedure has to be followed for erection of LP turbines.32.After final boxing up of all casings alignment of HP/IP to LPA rotor.33.LPA rotor to LPB rotor Alignment as per rotor catenary.34. Alignment of LPB to generator rotor.35.Release for secondary grouting


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Generator Erection Procedure

1. Marking of X & Y (Transverse & longitudinal axis) planes & transferring of reference benchmark level on to Generator deck area.

2. Chipping of loose materials on foundation.3. Blue matching of generator base plate packer plates.4. Blue matching of Generator anchor bolt plate to generator beck.5. Leveling of generator base plate packer plates & grouting of the same (only packer plate

area).

6. Leveling of generator base plates by water jar method.7. Erection of crane for lifting of Generator stator.8. Load testing of crane.9. Positioning of generator stator at unloading bay for lifting.10.Blue matching of Gen. Stator base plates.11.Removal of all temporary supports of stator and make arrangements for lifting.12.Lifting & positioning of the stator.13.Positioning & leveling of front & rear pedestals.14.Opening of generator front & rear end covers inspection of windings & cleaning of the

same.

15.Arrangements for threading of Gen. rotor( rear pedestal removal, end cover, seal oil seals(front & rear) opening.

16.Threading of generator rotor inside.17.Positioning of generator rear pedestal & loading rotor on to bearings.18.Leveling of generator stator.19.Air gap setting between rotor to stator.20.Inspection & closing of end shields.21.Fixing of front & rear seal oil clearances.22.Connection of seal oil piping.23.Hydro testing of generator water coolers & erection of the same.24.Connection of cooling water pipe lines to generator.25.Boxing up of bearings by setting the lub. oil clearances.26.Setting of oil catcher clearances.27.

Connection of jacking oil hose to bearings.

28.IR values checking up in each stage of boxing up of pedestals & during lub. oil pipe linesconnection time.

29.Positioning & leveling of Exciter pedestal.30.Positioning of exciter rotor.31.Swing test checking of exciter rotor & record the loading reading of exciter rotor on to

bearing.

32.Setting of bearing clearances, oil catcher clearances& boxing up of exciter pedestals.


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33.Alignment of exciter rotor to generator rotor.34.Release for secondary grouting.

After completion of secondary grouting all the foundation bolts are once again checked fortightness.

Final alignment of TG as per rotor catenary.

erectionofvariousmajorequipmentsinpowerproject128201141213pm

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