(wbb)d155a-000105asm - turbine installation manual

8/20/2019 (Wbb)d155a-000105asm - Turbine Installation Manual

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D F Power Systems Pvt. Ltd.,

SPECIFICATION

/DOCUMENT

INSTALLATION & MAINTENANCE MANUAL

OWNERM/s. NAVA BHARAT ENERGY INDIA LTD,

HYDERABAD

1x150 MW CFPP UNIT-1 PALONCHA (A.P.),

INDIA

D F POWER SYSTEMS PVT. LTD., HONGKONG

SOUTHWEST ELECTRIC POWER DESIGN

INSTITUTE CHENGDU, CHINA

DONGFANG TURBINE CO., LTD.

DOCUMENT NUMBER

(WBB)D155A-000105ASM REV

A

PROJECT

BTG CONTRACTOR

BTG CONSULTANT

TURBINE SUPPLIER


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DOC NO.

(WBB)D155A-

000105ASM

DESIGN 2011-10-19

CHECK 2011-10-19

VERIFICATION

2011-10-20

STD ENGINEER 2011-11-01

REVIEW 2011-11-01

APPROVE 2011-11-01


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Installation & Maintenance Manual （WBB）D155A-000105ASM

1

Revision Record

Revision Date Revision Explain

A Oct.2011 The First Promulgate


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1

Contents

No. Chapter Name Page Remarks

1 1 General 12 1-1 General Outline 1

3 2 Preparations before Installation 1

4 2-1 Unpacking Check before Acceptance &

Maintenance of Equipment

1

5 2-2 The Inspection and Cleaning-up of

Equipment before Installation

1

6 3 Steam Turbine Proper Installation 1

7 3-1 Foundation Check and Blocking Iron

Arrangement

2

8 3-2 Preparatory Assembly 2

9 3-3 LP Casing Installation in Place 2

10 3-4 Bearing Box Installation in Place 3

11 3-5 The Lower Half of HIP Outer Casing

Installation in Place

1

12 3-6 The Lower Half of HP Inner Casing

Installation in Place

3

13 3-7 The Upper Half of HIP Casing Installation

in Place

1

14 3-8 Bearing Installation and Rotor Centring 2

15 3-9 Casing& Diaphragm Carrier Centring 2

16 3-10 The Installation of HP Stop & Control Valve

and HP Main Steam Pipe

1

17 3-11 The Installation of IP Combined Steam

Valve and IP Main Steam Pipe

1

18 3-12 Diaphragm Centring 2

19 3-13 Throughflow Clearance 2

20 3-14 Conventional Assembly 7

21 3-15 Foundation Back Grouting 122 3-16 Couple Connection 2

24 3-17 Auxiliaries Installation 2

25 3-18 Laying Insulating Layer 1

26 3-19 Cleading Installation 1

27 4 Maintenance Requirements 1

28 4-1 Steam Blowpipe 3

29 4-2 Oil Flushing 2

30 4-3 The Fastening and Maintenance of Joint

Bolts

3


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2

31 4-4 The Inspection Items of Unit General

Overhaul and Minor Overhaul

2

32 4-5 Main Lubricating Parts and Lubricating

Requirements

1

33 4-6 The Use Directions for Special Tools 234 5 Appendix 1

35 5-1 Appendix1 The Weight of Large Components 1

36 5-2 Appendix2 Installation Flow Chart of Steam

Turbine Proper

1

37 5-3 Appendix3 Casing Joint Face Paint 1

38 5-4 Appendix4 Casing Combination

Requirements

1


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1-1

1 General

This instruction manual gives a brief account of the installation procedures of this steam

turbine unit body, and emphatically provides the drawings and technical documents that the

installation procedures at every step should refer to. Main inspection items and installation

precautions are also listed in the manual. Customers should compile construction techniques

according to the instruction manual requirements. As for the installation procedures, a construction

unit may make proper adjustments in accordance with field situation.

《Steam Turbine Body Certificate》records the general assembly & adjustment results of

this unit in the manufacturer pursuant to design requirements. Thus, the detailed installation

requirements of every relative part will not be enumerated one by one in this instruction manual.

This technical document should be referred to at the same time when installation is underway in

power plant.

This instruction manual gives the main maintenance items and requirements for the

purpose of compiling maintenance details by users.

If the installation data listed in this instruction manual do not conform to those in the

《Steam Turbine Body Certificate》, the installation data in the《Steam Turbine Body Certificate》

shall be the criteria for adoption.

This instruction manual does not list detailed construction requirements. The construction

unit may go ahead with its work pursuant to the SDJ53-83 Steam Turbine Chapter in 《Electrical

Power Construction & Acceptance Technology Specifications》.

As the steam turbine body has already been generally assembled prior to exworks and the

general assembly & adjustment between every sub-assembly have been finished according to the

design requirements, the power plant installation should be carried out based on the manufacturer

general assembly values as much as possible.

The drawings and technical documents this instruction manual deals with are only marked

with names, and delivery list should be consulted for the drawing numbers.

The weight table for large parts is listed in this instruction manual. Please see Appendix 1

for the users’ reference of choosing lifting appliances and tools.

This instruction manual also includes the installation procedure flow chart. Please see

Appendix 2 for the users’ reference of installation.


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1-1

1-1 General Outline

This unit is super-high pressure primary mid-reheat two casings double exhausts

condensing steam turbine with the last stage rotating blade 660mm high. The overall length of

the unit is 13.545m.

This unit completely adopts electrical control system.

Through the HP main stop & control valve located on the two sides of the unit, fresh

steam passes HP main steam pipe 、inlet pipe, and enter the HP casing. The HP section is

counterflow, butts with IP section, and shares a HP & IP outer casing with IP section. HP exhaust

enters IP casing through the IP combined steam valve located on the two sides of the unit after

being reheated. IP exhaust enters the middle part of the LP casing through cross-over pipes,

flows forward and backward separately, and into condenser through front- row and back-row

cylinders. The LP casing is divided into LP outer casing and LP inner casing.

The HP casing of this unit is double sheet cylinder structure with intercalated bed heating

system. Four nozzle boxes are fixed in the front end of the HP inner casing, and the fresh steam

enters the HP inner casing by the four inlet pipes which through the outer casing to inner casing

and the nozzle boxes. There is first section extraction behind the HP 7th stage , two-section

extraction at exhaust opening, and the 8th & 9

th

There are 3

stage diaphragms hare fixed on No.1 carrier ring.

The mid-split section of the HP inner casing use through-hole bolt. There are inner & outer

casing relative dead points in the HP inner and outer casings. To reduce the effects of heat

expansion on stator center, the HP & IP outer casing adopts lower cat-claw horizontal joint

support structure with the outer casing being supported on the front and middle bearing boxes.

Axial force is transmitted through push-pull structure and cat-claw cross key between the outer

casing、front bearing box and middle bearing box.rd

、4th 、 5

th sections extraction respectively behind the IP 6

th& 8

thstages

and at the exhaust opening. The IP 1st 、2

nd 、 3

rd stages diaphragms are fixed on No.2 carrier

ring, the 4th

、5th 、 6

th stages diaphragms are fixed on No.3 carrier ring, the 7

th 、8

th stage

diaphragms are fixed on No.4 carrier ring, and the 9th

、10th

The LP outer casing is made up of front、middle and back sections which are all welded

structure, and there is a spray protection device for preventing the casing from overheating in

front and back.

stages are fixed on No.5 carrier ring.

The HIP and LP rotors both are all integral rotors which are connected by right section,

and semi-flexible coupling connection is adopted between the LP rotor and generator rotor.The HIP rotors are supported by two bearings, the LP rotor front end and the HP & IP

rotors share one bearing for support, the rotor back end is supported by a bearing, and 4# bearing

is the front end bearing of the generator rotor. 1#、2#、3#、4# are elliptical supporting bearings,

and thrust bearing is the relative dead point of rotors.

The bottom design of the front bearing box has self-lubricating slider for improving

casing expansion. The relative dead point of the unit is set in the middle bearing box, at 2#

bearing center line leaning towards unit head 250mm.

The turning gear of this unit is located on the back bearing box with the rotating speed of

4.5 rpm.


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2-1

2 Preparations before Installation

Steam turbine installation is a piece of work that requires strict organization and high

techniques. Before the installation, proper preparations need to be made, such as making

installation plans, planning installation site, training installation personnel, and preparing

conventional installation tools, etc.. This chapter only emphatically brings forward the

requirements for unpacking check before acceptance & maintenance of equipment and the

inspection & cleaning of equipment before installation.


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2-1-1

2-1 Unpacking Check before Acceptance & Maintenance of Equipment

1

After being shipped to the site, the equipment should be unpacked for inspection before

acceptance. And the manufacturer should be informed by wire two weeks before acceptance of

sending personnel to take part in unpacking check before acceptance.

Check case number 、case quantity and name in accordance with packing list. Unpack and check

off.

Rust preventives should be smeared again on the equipment which cannot be installed

immediately after being unpacked. And then, the equipment should be repacked and sealed off.

As for uncovered assembly parts, rain hood should be added to the part where water log easily

occurs. Medium & small components should be stored in indoors warehouse for safe keeping

after inspections.

The finish machined surface which has been checked should be re-oiled against rust after it

is scoured.

Under the conditions that transport and storage are good, the guaranteed rust prevention

period of this product is one year.

2 If the equipment cannot be unpacked temporarily after being shipped to the site, the damage

conditions of equipment packing should be checked in time, and meanwhile, the damages should

be fixed, so that the equipment would not be eroded by rain、water 、fog and sand prior to

unpacking inspections. At the same time, the packing cases for rotor 、casing、 bearing box、HP

main stop & control valve and IP combined steam valve should be leveled up and supported

steadily.


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2-2-1

2-2 The Inspection and Cleaning of Equipment before Installation

Before unit installation, installation personnel must be familiar with all sorts of technical

documents & drawings the manufacturer supplies, and understand unit structure、 performance &

installation requirements.

1 Steam turbine installation in power plant is the chance to reexamine the manufacture quality

of the whole unit for the last time before it is put into operation, and also the chance for

thorough cleaning & clearing. Therefore, except the subassemblies which might be impaired

when overall disassembly is underway (e.g. the parts on the rotor 、turning gear 、main steam

valve base and such tight fits or transition fits parts as valve stem sleeve & the slide valve

sleeve of control subassembly, along with such copper pipe as oil cooler that is connected

through expanding pipes), the surface quality of other parts should be checked. Recheck fit

size、clearance and path, etc., together with the inspection on the motion accuracy &

flexibility of movable subassemblies. Disassembly will be conducted according to

subassembly performance and technical requirements.

2 Before subassemblies are disassembled, a good knowledge and understanding of drawings

and subassembly structure & assembly relations is necessary. The subassemblies should not

be knocked when disassembled, and after the subassemblies are reassembled, their parts

should keep originally relative positions whose clearance、interference and the motion

flexibility of path should conform to drawing requirements.

3

All subassemblies (except those which are not allowed to be disassembled) should be

thoroughly cleaned or cleared. After that, the machined surface of the subassemblies should

be smooth, rust-free and dirt-free. The non-machined surface that contacts working medium,

such as the inner & outer wall of pipelines, the inner & outer surface of HP & IP inner casing

and diaphragms carrier ring, the inside of bearing box and the inner & outer surface of

control subassembly cage, etc., should have no adhering sand 、enclosed slag、overlap and

other dirt after being cleared. When subassemblies are cleaned and cleared, special attention

should be paid to the cleanness and smoothness of drainage hole、 bearing oil hole、small

control subassembly hole and groove.

The above-mentioned cleanliness should be maintained till the unit start-up, therefore, after

the subassembly cleaning meets the afore-said requirements, further pollution and rust

erosion should be prevented.

4

Spectral analysis should be conducted on the alloy steel fasteners, which are used for such

subassemblies as casing、main steam valve、control valve、HP & IP main steam pipe and

carrier ring under high temperature conditions, to make sure that their material quality is all

right.

5

Recheck test should be carried out on any subassembly cage or pipeline、oil tank and

container (except casing and the subassembly cage which is not allowed to be disassembled)

that are specified in drawings & technical documents to undergo seal tests (hydraulic test、

kerosene test and watering test) .

6

Casing and rotor lifting appliance should be fully checked to see if there is any damage to

them before they are put to use, and load test should be done according to drawing

requirements.


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3-1

3 Steam Turbine Body Installation

This chapter describes in detail the construction sequence & requirements and installation

precautions of main installation steps for steam turbine body. As for the function and structure of

each subassembly, please refer to relevant instruction manuals and drawings. In this chapter there

are no detailed descriptions about them.

There are no requirements for construction techniques and installation tools in this instruction

manual, however, no matter what construction techniques and installation tools are adopted, they

must meet the requirements of drawings、《Steam Turbine Body Certificate》and this instruction

manual.


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3-1-1

3-1 Foundation Check and Blocking Iron Arrangement

1

After foundation is poured and maintenance is up to standard, steam turbine body

installation may be carried out. The foundation pouring quality should be inspected

before installation.

According to base frame & anchor bolt drawings and blocking iron arrangement plan, mark

the installation positions of base frame and blocking iron on the foundation. Check the quantity、

location and verticality of anchor bolt hole, and the inside of anchor bolt hole should be smooth

& clean without concrete stoppage.

Confirm the quantity & location of engineering embedded parts under positioning key &

locating pin of middle & rear bearing box, and make sure that the embedded parts are welded

firmly with main reinforced steel bar in girder.

According to base frame & anchor bolt drawings and steam turbine outline drawing, draw

lines on the foundation, and inspect the installation center 、datum mark & installation space of

front bearing box、HP & IP outer casing、middle & rear bearing box、LP casing、HP main control

valve and IP combined steam valve. Inspect embedded parts location and reserved groove

location & dimension correctness.

Inspect the placement correctness of condenser 、oil tank and oil cooler.

Outside the framework of steam turbine body, set a foundation deformation observation

point for monitoring foundation settlement and deformation.

2

Blocking iron arrangement

Mark the placement position of blocking iron, shovel away the loose layer of foundation

surface, bare the solid parts of the foundation, and ensure that the space with the loose layer

shoveled away is 30-40 mm wider than the periphery of the blocking iron; floor iron and the

foundation surface should contact close without tilting at four angles.

Adjust the floor iron of the blocking iron from vertical & cross direction to horizon with

level meter, and the datum mark of the floor iron should conform to drawing requirements.

The staggered area between two oblique blocking irons should not exceed 25% of their

areas.

Between oblique blocking irons, between blocking iron and base frame, there are 3-5 contact

points within every 25×25mm whose contact area should account for more than 70% of the gross

area, and 0.05 feeler gauge shall not enter the clearances between them. The entry depth is not

deeper than 5mm.

After installation & adjustment is finished, oblique blocking irons should be welded firmly by tack welding.

3 Base frame

According to the datum mark and center line marked on the foundation, the initial spotting

of LP casing base frame emplacement shall be conducted (initial spotting finish, lifting the base

frame, and installation & emplacement with LP casing combination at the preparatory stage);

3.1.1 After the base frame is in place, check the contact between the base frame and blocking

iron with 0.05mm feeler gauge, which should not enter the clearances between them.

3.1.2 Pursuant to Certificate requirements, initially adjust the datum mark of the base frame

to make every LP casing base frame on the same horizontal surface, and meanwhile,

find out the horizontal dimensions of each base frame and adjust the location


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3-1-2

dimensions of the base frame.

Emplacement & spotting of the base frame of middle & rear bearing box

After the base frame is in place, check the contact between the base frame and blocking iron

with 0.05mm feeler gauge, which should not enter the clearances between them.

Initial spotting two centers of base frame should basically conform to the center line of

steam turbine generator.

According to LP casing base frame position, adjust the datum mark & leveloff of the base

frame, and look for the cross horizon of it at the same time.

Condenser datum mark inspection

On the basis of base frame top surface, confirm condenser datum mark, and inspect

the flatness & datum mark of condenser neck and LP casing butting flange.


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3-2-1

3-2 Preparatory Assembly

Casing & bearing box preparatory assembly should go ahead in advance before they are in

place for shortening installation period.

1

The preparatory assembly of bearing box & base frame and LP casing & base frame

Front bearing box & base frame preparatory assembly:

Check DEVA slider & base frame slider groove, and the contact between stainless steel

slider and box slider groove. The contact should be even, and the contact area should not

be less than 75%. It is only permitted to shape & scrape the sliding surface of upper slider

and the back of lower slider when shaping & scraping. The axial excess of the upper &

lower slider is 25;

Check the contact between DEVA slider and stainless steel slider. Every slider should

contact equally, the contact area should not be less than 75%, and 0.03mm feeler gauge

shall not enter the clearances between them (before the final buckle-up of bearing box and

base frame, spray wear-in film lubricant).

Check vertical key & clamp plate clearance, which should conform to the requirements in

《Steam Turbine Body Certificate》.

Middle bearing box & base frame preparatory assembly:

Put the bearing box on the base frame, and check the contact between the box bottom and

base frame. The contact surface should be even, the contact area should not be less than

75%, and 0.03mm feeler gauge shall not enter the clearances between them;

Inspect vertical key & cross key clearance, which should conform to the requirements in


Rear bearing box & base frame preparatory assembly:

Put the bearing box on the base frame, and check the contact between the box bottom and

base frame. The contact surface should be even, the contact area should not be less than


Inspect vertical key clearance, which should conform to the requirements in《Steam Turbine

Body Certificate》.

2 Casing connection

For the convenience of LP outer casing installation & adjustment, recommend the

installation methods of LP outer casing front、middle and rear sections which are

connected on the assembly rig. The installation unit may connect them under the assembly

rig according to practical situations.Preparatory assembly should refer to relevant drawings of bearing box、 base frame、HP

& IP casing and LP casing, along with casing connection & sliding pin system portions in


2 LP outer casing & base frame assembly

2.1.1 Place the horizontal joints of LP outer casing front、middle and rear sections downwards

(take care to protect the horizontal joints), and check the contact between LP casing base

frame and platen. The contact should be even, the contact area should not be less than


2.1.2 Inspect the cross key clearance of front base frame, which should conform to the

requirements in 《Steam Turbine Body Certificate》.


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2.1.3 Smear lubricant on the key and base frame, fasten the base frame to LP casing platen,

ensure the single side clearance is not smaller than 3.5mm between linking bolt and the

LP casing platen hole, and remove temporary gasket after final localization.

2.1.4 Flush the spray cooling pipe of LP casing with 4～6kgf/cm2

2.2 The front、middle and rear sections connection of LP outer casing, along with outer casing

localization.

water, and seal it after

having been cleaned (Don’t install sprayers at this moment).

2.2.1 Before connection, clear vertical flange face;

2.2.2 The front、middle and rear sections of LP outer casing lift the LP outer casing lower half

and upper half onto the assembly rig for connection, inspect the height misplacement

quantity at horizontal joint flange connection, and re-check the flange pit axiality of front

& rear gland seal;

2.2.3 Adjust the cross horizon of lower-half three-section casing, and make the three-section

cross horizon agree with each other;

2.2.4 Adjust the vertical horizon of lower-half three-section casing, and make the vertical

horizon of the three-section casing agree with each other;

2.2.5 According to the general drawing requirements of LP outer casing, install eccentric pin

bush & pin respectively, and weld them firmly;

2.2.6 Under the conditions of guaranteeing the articles of 2.2.2～2.2.4, fasten the joint bolts of

vertical flange.


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3-3-1

3-3 LP casing installation in place

1

The following work should be done before LP casing lower half is in place.

While lifting lower-half outer casing, be sure to place it smoothly and carefully, avoid

making the sliding surface of platen & base frame roughcast, and do not affect the

blocking iron arrangement of the base frame. The base frame and anchor bolt should be

aligned.

Condenser is already in place;

Install the inner baffle plate that back grouting needs;

2

LP outer casing in place

Lift LP casing lower half onto assembly rig with the lifting appliances supplied by

manufacturer.

LP outer casing lower-half spotting is initially conducted by pulling steel wire or using

optical collimator, to ensure its vertical center line agrees with foundation reference center line

and make LP casing exhaust center comply with condenser center.

Half empty casing load shall be distributed on LP outer casing lower half. When adjusting

casing load distributions, the casing should be in a free state, the cross & vertical key of dead

point should be taken out, and its vertical & cross horizon be considered comprehensively to

make casing load distribution go ahead harmoniously with horizon-seeking, and meanwhile,

meet the requirements specified by the manufacturer.

3

LP inner casing lower half in place

Before installation in place , lower half extraction pipes should be lifted in.

When installed in place, be sure to notice the marks of “T” and “G” on the front & rear end

of casing. “T” end is on the side of steam turbine head while “G” end on the side of generator.

According to《Steam Turbine Body Certificate》, adjust LP inner casing center & horizon, reset

vertical & cross key, re-assemble the regulating gasket of inner casing shoe plate, and inspect the

clearances which should conform to the requirements in 《Steam Turbine Body Certificate》.

On the basis of front & rear gland seal pit of LP outer casing, re-check LP inner & outer

casing axiality which should meet the requirements specified by the manufacturer.

4 Adjust base frame and screw down anchor bolt

Adjust the oblique blocking iron under the base frame, so that LP outer casing platen can

contact the base frame; inspect the ambient clearances which 0.05mm feeler gauge should not

enter between the platen and base frame;Re-check the total clearance of dead point cross key of the base frame on two sides;

Disassemble dynamometer;

Equally screw down the anchor bolts of LP casing base frame with the force moment of

1500N.m. After all the anchor bolts are screwed down, re-measure casing vertical & cross

horizon which should be in conformity with the data before the anchor bolts are screwed down;

Re-inspect the contact clearance between LP outer casing platen and base frame;

Re-measure LP inner & outer casing axiality, and vertical & cross horizon shall conform to

requirements.

5 Buckle up LP inner casing upper half

Lead LP inner casing upper half in place with guide post, and inspect horizontal joint flange


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3-3-2

clearance which should come up to drawing requirements.

Screw down one third of the horizontal joint flange bolts at intervals, inspect the horizontal

joint flange clearance which 0.05mm feeler gauge cannot enter, and some separate part the feeler

gauge can enter shall not exceed one third of flange width. When LP inner casing upper half is

finally buckled up, forward & backward stage 1～4 diaphragms should be fixed in the upper half

casing.

6 Buckle up LP outer casing upper half

Lead LP outer casing upper half in place with guide post, and inspect the horizontal joint

flange clearance which should come up to drawing requirements.

Screw down one third of horizontal joint flange bolts at intervals, inspect the horizontal joint

flange clearance which 0.05mm feeler gauge cannot enter, and some separate part the feeler

gauge can enter shall not exceed one third of flange with.

7 After inspections are finished, lift the upper halves of inner & outer casing apart so that

subsequent installation work might go ahead.

8

The base frame locating pin installation —— the dead point on two sides of LP outer

casing

After anchor bolts are screwed down, fabricate the base frame locating pin, the dead point

on two sides of LP outer casing, and when the fabrication is underway, be sure to prevent

welding deformation which would result in casing offset.

Drawing 3-3-1

Locating pin

Base frame

O n - s i t e a s s e

m b l y c l e a r a n c e

Engineering embedded parts


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3-4-1

3-4 Bearing box installation in place

After LP casing is in place, middle、rear and front bearing boxes may be installed. After

initial spotting by pulling steel wire, confirm every bearing box position based on LP outer

casing lower half and HP & IP outer casing lower half, and then, according to Section 3-8 Rotor

Centring requirements, lift in every rotor, and adjust the deflector pit center of the rotor &

bearing box to the requirements; in accordance with shafting installation leveloff, center rotor

couple; adjust the datum mark of every bearing box, and center the rotor at the front & rear gland

seal pit of casing.

During the unit operation, casing heat expansion would result in front bearing box sliding

forward and backward, so take care to check the bottom slider of front bearing box and the lower

slider of front bearing box base frame, which should be cleaned and contact well.

Spread supramoly or graphite powder on the bottom vertical keys of front、middle and rear

bearing boxes to ensure the bearing box and key slide smoothly, and all vertical key clearances

between the bearing box and base frame should remain on the same side without undesirable

deformation, to prevent sliding pin system from getting stuck while operation is underway.

When installation is carried out, please note that front bearing box can move in a vertical

direction, but it cannot move in a cross direction; while middle bearing box is dead point box

which cannot move in any direction, therefore, the installation of its clamp plate、vertical key and

cross key must be taken seriously.

Installation procedures are as follows:

1.

Preparations before bearing box is in place:

Before being installed in place, the bottom surface of bearing box and base frame should be

cleaned.

2. Bearing box in place:

Install middle、rear and front bearing boxes in place; due to the demand for unit heat

expansion, enough heat expansion capacity should be reserved along the axial direction of front

bearing box and base frame.

On the basis of the inside deflector pit of front、middle and rear bearing boxes, roughly look

for the bearing box centers by pulling steel wire.

Adjust the end face locating dimensions of middle & rear bearing box and LP outer casing,

to meet the Certificate requirements.

According to the requirements for LP rotor’s being in place in Section 3-8, install the LP

rotor in place, adjust the rotor, bearing box deflector pit center and LP outer casing front & reargland seal pit center to meet the requirements.

3. Initially install HP & IP outer casing lower half in place.

Adjust the axial positions of front & middle bearing box to meet the requirements in《Steam

Turbine Body Certificate》.

4.

According to the requirements for HP & IP rotor’s being in place in Section 3-8, install the

HP & IP rotor in place, adjust the rotor and bearing box deflector pit center to meet the

requirements, and after that, in accordance with the requirements for rotor couple centring,

bearing box datum mark may be adjusted through the adjustment of the blocking iron under

base frame.

5.

After all bearing boxes are finally located, the bearing box anchor bolts and front & middle


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3-4-2

bearing box anchor bolts shall be screwed down with the force moment of 1500N.m.

6. After bearing box anchor bolts are all fastened, finally check and record the datum mark of

the bearing box, the center position of vertical & cross direction, along with vertical & cross

horizon data. The moments of force for screwing down the double-threaded stud between the

bearing box and base frame are:

M30 900N.m

M36 1200N.m

M42 1350N.m

7.

The dead point key installation on the two sides of middle bearing box base frame:

After anchor bolts are screwed down, according to attached drawing, assemble dead point

key and make the clearance comply with drawing requirements, and then, weld the dead

point key with embedded parts firmly.

8. Lift out LP outer casing lower half

Disassemble the joint bolts between LP outer casing and base frame, and lift out the LP outer

casing from assembly rig.

According to LP outer casing drawing requirements, seal weld the vertical flange face

connections of front、middle and rear sections of outer casing upper & lower half. The welding

rod is E4303, the welds should be flat and look good, and the bilaterally symmetrical welding

should be conducted.

9 Reset LP casing in accordance with Section 3-4.

Drawing 3-4-1

Total assembly clearance on two sides

Engineering embedded parts


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3-4-3

Drawing 3-4-2

Front box

Generator sideSteam turbine head

Base frame


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3-5-1

3-5 The lower half of HIP outer casing installation in place

1

Install cat-claw chock and push-pull key on the front side of middle box, install cat-claw

chock and push-pull key in front box, which shall conform to drawing requirements.

Confirm that the haul-back device of front bearing box has been disassembled.

2 Before the lower half of HIP outer casing is in place, the admission pipe of HIP lower half

should first be lifted onto platform.

3 Lift the lower half of HIP outer casing onto assembly rig, and adjust the axial position of

front box to make locating dimensions comply with the ex works record of Certificate.

4

According to Casing centring requirements in Section 3-9, center rotor at front & rear gland

seal pit of HIP outer casing to meet the manufacturer’s requirements.

5 Adjust the vertical & cross horizon of HIP outer casing lower half. (Please refer to the

manufacturer’s record value)

6 When the manufacturer’s final assembly is underway, the half-empty casing load distribution

of HIP casing has been made, therefore, on-site installation is only restore it according to the

vertical & cross horizon value and load distribution value at the time of the manufacturer’s

final assembly.

7 Supramoly or graphite powder should be spread on all sliding keys while they are being

installed.

8 The haul-back device of front bearing box and casing shall be assembled in accordance with

drawing requirements.


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3-6-1

3-6 The lower half of HP inner casing installation in place

1

Clean the lower half of outer casing;

2

Before the lower half of HP inner casing is in place, purpose-made nuts should all be

assembled. Please see Drawing 3-6-2.

3 Inspect the pressure tube & drain pipe of inner casing lower half which should be intact and

undamaged; when the lower half of inner casing is laid down, guide rod should be used to

align the pressure tube and drain pipe with the hole on the lower half of outer casing. Please

see Drawing 3-6-1.

4

Before HP & IP inner casing is finally in place, assemble every measuring element of lower

half. According to HP inner casing drawing, check every component of inner & outer casing

lower half which shall be complete and in its place.

5 According to HP casing drawing, confirm that the lower half of HP inner casing and

thermocouple & lead are already installed ,which is used to measure the inner & outer wall

temperature of inner casing lower half, and clean the lower-half inside of HIP outer casing.

6

Install the lower half of HP inner casing in place by using the cat-claw chock, supplied by

the manufacturer.

7

Accurately adjust the coaxially of inner & outer casing.

Check the front & rear bottom vertical key between inner casing and outer casing, together

with the clearance between the supporting ledge top of inner casing and outer casing, which

shall conform to the requirements in《Steam Turbine Body Certificate》.

8

After the lower half of HIP inner casing is finally in place, refer to HIP admission pipe

drawing for the installation of lower-half admission pipe.

Part No. Drawing No. Description

1 D00,010,328 Retention pin

2 D00,010,330 Stop block

3 D00,010,329 Hanging screw

When installation is underway, first assemble Part 3, hang up purpose-made nut, and then,

assemble Part 2, replacement part 2, ensure the clearance is ranging from 0.1 to 0.15, and finally

put Part 1 in its designated position from nut hole, rivet it firmly.


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3-6-2

外缸

Drawing 3-6-1

Inner casing

Outer casing

Outer casing

Guide rod ( Self-provided by power plant )


24/68


3-6-3

Drawing 3-6-2

Inner casing lower half

Rivet firmly

Purpose-made nut

Clearance

C l e a r a n c e 0 . 3 ～ 0 . 5


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3-7-1

3-7 The upper half of HIP Casing Installation in Place

1.

Buckle up the upper half of inner casing, install locating pin, screw down 1/3 bolts, and

check the joint surface clearance of inner casing which 0.03mm feeler gauge should not

enter.

2. Buckle up the upper half of outer casing, install locating pin, screw down 1/3 bolts, and

check the joint surface clearance of outer casing which 0.03mm feeler gauge should not

enter.

3.

Inspect the vertical key clearance of front、rear and top ends between inner casing and

outer casing, which shall conform to the requirements in《Steam Turbine Body

Certificate》.

4. Before HIP outer casing is finally buckled up, according to HP inner casing drawing,

check & confirm every measuring element on inner casing is already installed, every

component of inner casing upper half is complete and in its place.

5.

After the upper half of HP inner casing is finally in place, refer to HP & IP admission

pipe drawing for the installation of upper half admission pipe.

6. When the upper half of HP inner casing is finally in place, the upper half of HP stage

2～7 diaphragms should be installed in inner casing upper half.


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3-8-1

3-8 Bearing Installation and Rotor Centring

After bearing box & casing is in place and their initial spotting is done, rotor centring

work should go ahead with the following procedures.

Before the rotor is in place, lift in bearing lower half, and meanwhile, relevant components

must be cleared carefully to prevent bearing journal and bearing babbit from being damaged;

before LP rotor is in place, the lower half of LP backward stage 1 diaphragm must be first

installed, please see Section 3-9 for Diaphragm Centring Work.

Before LP rotor centring begins, generator stator should be in place.

1

False liner is used in installation; 3# & 4# bearing installation and LP rotor centring.

Re-install 3# & 4# bearing, check and make sure the following items conform to drawing

requirements.

The excircle of bearing chock contacts bearing pedestal pit;

Spherical surface fits; check each horizontal joint face of bearing, which should contact well,

and 0.05mm feeler gauge shall not enter.

The spherical joint face of 3# & 4# bearing liner body and bearing liner carrier must be

smooth, and their contact area shall not be less than 70% with even distribution.

Inspect the inner hole dimension of bearing liner, which shall conform to design

requirements.

Check & clear bearing liner and the oil inlet & oil drain hole of bearing box which should be

clean and clear.

Add the adjusting shim of datum mark between the adjusting chock of 3# & 4# bearing

lower half and the bearing liner carrier to regulate the datum mark, please see《Steam

Turbine Body Certificate》for detailed specific data.

Put the false liner for installation into middle bearing box.

Spread clean turbine oil on the bearing liner surface, lift in LP rotor; the axial clearance

between LP backward stage 1 blade wheel and diaphragm is the installation reference for

the LP rotor’s in place.

Check & adjust rotor leveloff, the axiality of LP rotor and oil retaining ring pit, and the

clearance between the inner hole of bearing liner and bearing journal; which should all

conform to the requirements listed in《Steam Turbine Body Certificate》.

After the above-mentioned requirements are met, re-examine the fastening force of each

group of blocking iron, maintain basically equal fastening force, and fasten the anchor bolt

of LP casing base frame.2

Thrust bearing in place

Check the horizontal joint face of bearing, which should contact well, and 0.05mm feeler

gauge shall not enter.

The spherical joint face of thrust bearing carrier and thrust bearing body must be smooth,

and their contact area shall not be less than 75% with even distribution.

Check spherical fit clearance which should conform to Certificate requirements.

The oil drain hole of bearing box should be clean and clear.

Inspect the measuring elements of thrust pad which shall not be loosened.

Install the lower half of thrust bearing in place; it is not permitted to install front & rear

thrust pad and backing ring at this moment.


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3-8-2

3 1# & 2# bearing installation and HP & IP rotor centring

Re-install 1# & 2# bearing, and 1# & 2# bearing inspection & assurance items shall be the

same as those of 3# & 4# bearing.

Spread clean turbine oil on bearing liner surface, lift in HP & IP rotor, the axial clearance

between adjusting blade wheel and nozzle box shall be the installation reference for HP & IP

rotor’s in place.

Inspect rotor leveloff, according to shafting couple centring requirements, set rotor

installation leveloff, and determine the datum mark of bearing box. (proceed simultaneously with

Bearing box in place in Section 3-4)

Check & adjust the alignment of HP, IP and LP rotor couplings, which should conform to the

requirements in《Steam Turbine Body Certificate》. At the same time, check the axiality of HP, IP

& LP rotors and oil retaining ring pit, which should conform to the requirements in《Steam

Turbine Body Certificate》.

After rotor center is adjusted, adjust the axiality of HP & IP casing front & rear gland seal pit

and the rotor, along with the axiality of LP front & rear gland seal pit and the rotor (proceed

simultaneously with casing’s in place).

4

Check the clearance between the bearing liner inner hole of supporting bearing and bearing

journal, along with the bearing oil retaining ring clearance.

5 Check the oil-seal ring clearance of thrust bearing.

6 Install the upper halves of bearing 1# ～4#, and check the top clearance of supporting

bearing.

7

After the above-mentioned requirements are met, re-examine the fastening force of each

group of blocking iron under bearing box base frame, maintain basically equal fastening

force, and fasten the anchor bolt of the bearing box base frame.


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3-9-1

3-9 Casing &diaphragm carrier centring

Casing & diaphragm carrier centring is very important in the whole installation work.

In the centring work, environmental temperature change effect on centring data should be

taken into account, such as taking the step of measuring each time within a period of time to

decrease errors.

In measuring work man-induced measuring mistakes should be prevented, and the

measuring work should be done by one person as much as possible.

Casing centring may proceed with two steps: the first step is the state of buckling upper half

casing & diaphragm carrier, that is, casing combination centring. The second step is the state of

lifting away upper half casing & diaphragm carrier, that is, casing detachment centring. Buckling

upper half casing may go ahead interspersedly with Casing in Place of Section 3-6 to Section

3-10; in the state of buckling upper half casing, HP & IP main steam pipes and HP & IP outer

casing welding must be carried out, along with the connection of LP casing and condenser; and

meanwhile, HP main steam stop & control valve & IP combined steam valve shall be installed.

After the above work is finished, horizon & center data should be re-inspected which shall be

re-measured according to original measuring position after the upper half casing and diaphragm

carrier are lifted away.

Before the carrier ring is in place, its upper half and lower half should be combined; inspect

joint surface clearance which shall conform to drawing requirements.

The purpose of casing combination centring is to measure the center differences of casing

combination and casing detachment which are to be provided as the correction basis for

diaphragm & gland seal centring in the state of casing detachment in the future.

1

Casing combination state

1.1 Centring work preparations:

Cool screw down 1/3 joint surface flange bolts of inner & outer casing, and eliminate casing

joint surface flange clearance. Cool screw down 1/2 or all bolts of diaphragm carrier joint

surface, and eliminate joint surface clearance.

1.2

Centring inspection:

All parts to be measured shall be measured twice.

1.3 Data confirmation:

All measured center data shall be recorded and analyzed, compared with manufacturer’s

general assembly data, and after they are confirmed all right, record their results.

1.4

According to requirements, screw down casing cat-claw bolt, check & record each itemdimension, remove the gasket under front bearing box clamp plate, re-examine its clearance

and record it after it is confirmed all right, and then, screw down all clamp plate bolts with

the tightening force moment of 900N.m.

2 Casing detachment state

2.1 The work which needs to be done before upper half casing & diaphragm carriers are lifted

away:

Before the upper half of HP & IP casing is lifted away, install HP main steam stop & control

valve and IP combined steam valve, weld HP & IP main steam pipe with casing body (see

Section 3-10 and Section 3-11), along with the welding of LP casing and condenser; when

the welding is underway, a dial indicator shall be erected to monitor the operations.After the


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3-9-2

above work is finished, the center shall be re-checked again on the basis of bearing 1#～

4# oil retaining ring pits.

2.2

Center change correction:

If the center changes so much from installation & welding, serious analyses should be

made, and the welding zone shall be modified through hammering or be re-welded after

the welds are cut open.

2.3 Upper half casing detachment:

2.3.1 Disassemble HP & IP outer casing, HP & IP inner casing, diaphragm carrier, LP outer

casing and LP inner casing joint surface flange bolts, measure outer & inner casing joint

surface flange clearance, and record it at the same time.

2.3.2

Lift away the upper half of HP & IP casing, diaphragm carrier and the upper half of LP

casing; at all measuring points of front、middle & rear bearing boxes and HP & LP casing,

re-inspect centring situations and record them. Study the records of casing buckle-up &

detachment center.

2.4

Different kinds of casing & bearing box key installation or inspection:

Install vertical key between front & middle bearing box and HP casing; install vertical

key between middle & rear bearing box and LP casing, and inspect fit clearance.

2.5 Casing & bearing box horizon re-inspection:

Fully re-inspect casing & bearing box vertical horizon which is in conformity with rotor

leveloff. Fully re-inspect casing & bearing box cross horizon.


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3-10-1

3-10 HP main steam Stop & control valve & HP main steam pipe

installation

After casing centring is finished, steam valve & pipe installation shall go ahead under the

state of upper & lower half casing combination in the order that HP is ahead of IP.

1 Refer to HP main steam control valve installation drawing and HP main steam control valve

supporter drawing for the location of the HP main steam control valve supporter.

2 Refer to HP main steam pipe drawing for the temporary fixation of HP main steam control

valve according to the position before cold pulling. Register HP main steam pipe interface &

admission pipe interface, and welding shall be conducted strictly according to electrical power

construction & acceptance technology specification (Welding Chapter) requirements; after

that, stress shall be relieved. The welds shall go through ultrasonic or radiation flaw detection,

and hydraulic test shall be carried out on the pipe section with flanges on two ends in

accordance with drawing requirements. After the welding of HP main steam pipe is over,

casing center should be re-inspected.

3

After main steam pipe is welded, according to the numerical values and requirements from HP

main steam pipe drawing, axial and cross cold pulling shall be conducted, and after confirmed

all right through inspection, weld adjusting gasket, base plate and foundation embedded iron.

When main steam pipe & HP main steam pipe and valves are connected & cooled, it shall be

guaranteed that the valves make no move in any directions.

When HP main steam pipe is welded with casing and valves, the casing & valve deformation

and casing center change should be prevented.

4

HP main stop & control valve、HP main stop & valve manipulation seat、HP control valve

manipulation seat、HP main stop & valve actuator and HP control valve actuator, etc. have

already been assembled and adjusted in the manufacturer, and the user must re-assemble &

adjust them strictly pursuant to the manufacturer’s drawing requirements after on-site

disassembly & cleaning-up is completed. New unit operation should undergo the thermal state

adjustment of manipulation structure in accordance with relevant drawing file, the batt gasket

temporarily used for shipment (to prevent valve discs from knocking against each other),

padded between valve disc and valve seat, must be removed when HP main stop & control

valve is cleaned-up.

5

The position for the installation of creep tester should be covered with a protection hood, and

the insulating layer here shall be detachable. Before installation, measure and record the initial

dimensions of the creep tester.


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3-11-1

3-11 IP combined steam valve & IP main steam pipe installation

1

Before IP combined steam valve is in place, IP main steam pipe and reheat hot leg pipe

should be first installed.

2 Temporarily locate IP combined steam valve supporter. Please see IP combined steam valve

supporter drawing.

3 Register IP main steam pipe interface & admission pipe interface, and weld them according

to “Electrical Power Construction & Acceptance Technology Specifications (Welding

Chapter)” requirements; after that, stress shall be relieved, and welds quality be inspected.

According to IP main steam pipe drawing requirements, hydraulic test shall be conducted.

4 After the welding of IP main steam pipe is over, casing center should be re-inspected. When

reheat hot leg & IP main steam pipe and valves are connected & cooled, it shall be

guaranteed that the valves make no move in any directions.

When IP main steam pipe is welded with casing and valves, the casing & valve deformation

and casing center change should be prevented.

5

Install and adjust the supporter according to IP combined valve supporter drawing.

6

IP combined steam valve、IP control valve manipulation seat、IP main stop & valve

manipulation seat、IP control valve actuator and IP main stop & valve actuator have already

been assembled and adjusted, and the user must re-assemble & adjust them strictly pursuant

to the manufacturer’s drawing requirements when on-site disassembly & cleaning-up is

underway. New unit operation should undergo the thermal state adjustment of manipulation

structure in accordance with relevant drawing file, the batt gasket temporarily used for

shipment (to prevent valve discs from knocking against each other), padded between valve

disc and valve seat, must be removed when IP combined steam valve is cleaned-up.

7 The creep tester installed on pipes shall measure and record initial dimensions prior to

operation. The position for the installation of the creep tester should be covered with a

protection hood, and the insulating layer here shall be detachable.


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3-12-1

3-12 Diaphragm centring

After casing、diaphragm carrier and rotor centrings are finished, diaphragm and gland seal

centring should be conducted.

Before the gland seal and diaphragm are in place, the casing、 bearing box、diaphragm carrier 、

diaphragm and gland seal should be cleared carefully.

Before the installation of diaphragm and gland seal, supramoly or graphite powder should be

spread in fit groove, especially on high temperature section.

Before LP diaphragm and gland seal are in place, the installation of condenser should have been

completed, and generator stator been basically in place.

1

Preparations prior to diaphragm & gland seal’s in place:

Inspect the parts attached to diaphragm and gland seal, which should be complete.

Combine the upper & lower half of diaphragm gland seal; inspect the joint surface clearance

which should conform to drawing requirements.

Assemble the parts attached to diaphragm and gland seal, and screw down all bolts.

2

Diaphragm assembly:

All diaphragm lower halves should be installed in casing and diaphragm carrier according to

their marks, and the joint surface shall basically maintain horizontal; the assembly clearance

between the locating key of diaphragm bottom and casing & diaphragm carrier key groove

shall meet drawing requirements.

3

Gland seal assembly:

The lower half of HP & IP gland seal should be put into casing or fixed on it according to its

mark, and locating pin shall be installed. Put the lower half of LP gland casing into LP outer

casing.

4 Diaphragm & gland seal centring and adjustment:

Pull tight steel wire on the basis of front & rear bearing box oil retaining ring pits, take the

centring measurements of all diaphragms and gland seals, compare & analyze the measurements

with the manufacturer’s record results, and take into account the differences between rotor

flexibility and steel wire flexibility, along with the effect of casing combination on the center.

If the center needs to be adjusted, the upper & lower gasket of hanging pin and locating pin

should be fitted as usual.

5 Final centring:

After the adjustment of all diaphragms and gland seals is over, final centring measurement

should be taken; at this time rotor should be lifted in, and confirm that all diaphragm &gland seals centrings meet Certificate requirements.


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3-12-2

Drawing 3-12-1

Drawing 3-12-2

Steel wire

Measured with micrometer gauge


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3-13-1

3-13 Throughflow clearance

After diaphragm centring work is completed, kinetic & static clearance of throughflow part

should be measured. When the throughflow clearance is measured, the following points should

be kept in mind:

The axial clearance between adjusting blade wheel and nozzle box should be the installation

reference for HP & IP rotor’s in place. Install the front & rear thrust pad and front & rear backing

ring of thrust bearing, place rotor thrust collar close to work pad to make the rotor in working

position; the axial clearance between LP backward stage 1 diaphragm and blade wheel shall be

the installation reference for LP rotor’s in place.

a)

When measuring throughflow clearance with oblique ruler, proper methods must be

adopted, and measurements be accurate.

b) When emergency governor fly ring guide post is in horizontal position, measure axial

throughflow clearance once and record it; when the emergency governor fly ring guide

post is in the position of 900

c)

Inspect all radial clearances with the rotor by applying rubber adhesive plaster (they

may be inspected by pressing lead wire).

, measure it again for re-check..

The working procedures are as follows:

1 Rotor in place:

Based on the axial clearance between nozzle box and adjusting blade wheel, that is, the

installation & location reference, put HP & IP rotor in place.

Based on the axial clearance between LP backward stage 1 diaphragm and backward stage 1

blade wheel, that is, the installation reference, put IP rotor in place. Re-inspect the rotor center.

2 Thrust bearing installation & adjustment:

Check front & rear thrust pad thickness, and record it.

Install rear thrust pad & rear backing ring, push HP & IP rotor towards the generator side,

and make the thrust collar close to the rear thrust pad.

Install front thrust pad & front backing ring, and measure the total clearance value of the

thrust pad.

3 Measure throughflow axial clearance:

Measure all axial clearances of throughflow part between motion and still with oblique ruler;

all these clearances need to be measured on both left side and right side for two groups of data,

and be recorded at the same time.

When emergency governor fly ring guide post is in horizontal position, and when it rotates90

0

4

Measure diaphragm gland seal clearance, HP、IP & LP end gland seal clearances, and the

gland seal clearance between HP and IP:

, rotor shall be measured once respectively, and the former data shall be used as record values.

Measure the axial clearance between the gland seal long teeth of HP & IP section and the

rotor shoulder; initially measure the radial clearance between the gland seal teeth and rotor

surface with feeler gauge.

Initially measure the radial clearance between the gland seal teeth of LP section and rotor

surface with feeler gauge.


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3-13-2

5 Measure the radial gland seal teeth clearance of diaphragm:

Measure the axial clearance between radial gland seal teeth of diaphragm and the dummy

club of rotating blade shrouding; initially measure the radial clearance between the radial gland

seal teeth of diaphragm and rotating blade shrouding with feeler gauge.

Initially measure the radial clearance between the gland seal teeth of diaphragm root and the

blade wheel shoulder of rotor with feeler gauge.

6 Inspect rotor beat values:

Rotate the rotor, and inspect the beat values of HP & IP rotor.

Rotate the rotor, and inspect the beat values of LP rotor.

Measure the axial clearance between HP & IP rotor coupling and LP coupling end faces, and

inform the manufacturer of the measurements so that it can prepare the adjusting gasket of

coupling and coupling bolt length accordingly.

7 Inspect all radial clearances with rubber adhesive plaster:

Lift HP & IP rotor and LP rotor.

Stick two rubber adhesive plasters on the lower halves of all diaphragm gland seals

(including the gland seals at rotating blade top & root and diaphragm inner diameter), and the

lower half bottom center of shaft end gland seal, along with each gland seal arc section; after

rotor is in place, rotate the rotor, and make certain the radial clearance of lower-half gland seal

teeth through the scraped marks and thickness of the rubber adhesive plasters.

Stick the rubber adhesive plasters with different layers, repeat the steps of 7.1 & 7.2, and

determine the maximum & minimum clearance values.

Stick two rubber adhesive plasters on the upper halves of all diaphragm gland seals and the

upper-half top center of shaft end gland seal, along with each gland seal arc section; install all

diaphragms and gland seal upper halves in place respectively, rotate the rotor, and make sure the

radial clearance of upper-half gland seal teeth through the scraped marks and thickness of the

rubber adhesive plasters.

Stick the rubber adhesive plasters with different layers, repeat the step 7.4, and determine the

maximum & minimum clearance values.

Record the seal teeth radial clearance values of all diaphragm gland seals、shaft end gland

seal on top & bottom and on left & right side.


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3-14-1

3-14 Conventional assembly

The purpose of conventional assembly is: after throughflow assembly is confirmed up to

standard and before casings are formally combined, give all subassemblies in the steam turbine

body a thorough clean; after the cleaning is confirmed all right, re-assemble them and combine

the casings.

When the conventional assembly is underway, the following points should be kept in mind:

a) Conduct complete cleaning-up;

b)

Screw down fasteners completely;

c)

Make sure that the component parts shall be lubricated which need lubricating.

d)

Throughflow re-assembly values should tally with centring record;

e) It is not permitted to let other foreign objects or tools drop into the throughflow interior

when re-assembly is underway.

After the lower-half re-assembly is finished, the upper-half parts should be immediately

re-assembled and the casings be buckled up to ensure that the casings and the interior of

bearing box are clean.

The working procedures are as follows:

1

HP & IP casing lower half clearing:

Carefully blow clean HP & IP inner casing and the lower half of diaphragm carrier with

compressed air, confirm that there are no foreign objects or tools between HP & IP outer

casing and HP & IP inner casing or diaphragm carrier, and make sure that casing cat-claw

and the hanging pin bolts on diaphragm carrier are already screwed down.

2

LP casing lower half clearing:

Carefully blow clean LP inner casing lower half with compressed air, and confirm that there

isn’t any other foreign object or tool between LP inner casing and LP outer casing.

Blow clean spray pipe and sprayer with compressed air, confirm that the carrying bolts of LP

inner casing are already adjusted and screwed down, assemble the sprayer, and tack—weld it

on the turning seat.

3

diaphragm lower half assembly:

Confirm that hanging pin bolts are already screwed down.

Clean diaphragm.

Check the clamp plate of gland seal to see if it is already screwed down.

Check the diaphragm gland seal groove bottom to see whether there is any small hole for

balancing steam on it.Re-assembly.

4

Gland seal lower half assembly:

Clean gland seal lower half, inspect the gland casing chamber which shall have no foreign

objects or tools, and check the gland seal teeth to see if they are awry .

Confirm that hanging pin bolts are already screwed down.

Re-assembly.

5

Bearing lower half assembly:

Blow clean oil supply line (bearing box) with compressed air.

Blow clean oil return pipe and peep pipe (bearing box) with compressed air.

Clean up supporting bearing surface、thrust pad 、adjusting ring & spherical surface and oil


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3-14-2

admission pipe.

Supply small amount of lube oil for the lower half, and then, re-assemble it.

6

Rotor assembly:

Clean up and inspect rotating blade.

Inspect shrouding.

Clean up & inspect coupling surface and bearing journal surface; install the adjusting gasket

of HP & IP rotor coupling.

Re-assemble rotor and re-inspect rotor flexibility.

Re-assemble front & rear thrust pad.

Provide lube oil for all bearings, rotate the rotor, re-inspect all throughflow clearances and

the fit clearance between supporting & thrust bearing and the rotor.

The final record of throughflow clearance.

Install bridge gauges on each bearing liner, measure the clearance between the bridge gauges

and bearing journal top, and imprint the clearance value on corresponding bridge gauges as the

comparison criterion for future bearing journal wear.

7

Assemble supporting & thrust bearing upper half, and re-check supporting bearing top

clearance.

8

Bearing box upper half assembly:

Inspect oil retaining ring teeth to see whether they are awry or not.

Carefully clean up the inner surface of bearing box lower half and upper half.

Measure & adjust the clearance between oil retaining ring and the up & down、left & right

side of the rotor, and particularly, the bottom clearance must be carefully measured.

Inspect & measure the axial & radial clearances between rotor coupling hood and rotor in

rear bearing box, and record them.

Register the interference quantity of bearing gland and bearing chock, and according to the

force moment value of cold screw-down required in the Instruction Manual, screw down bearing

gland bolts.

Temporarily assemble bearing box cap, and inspect joint surface clearance.

9

Diaphragm upper half installation:

Clean up every stage diaphragm.

Inspect the gland seal teeth to see whether they are awry or not.

Assemble the joint surface locating pin of diaphragm upper half, supply lubricant to the

thread part when the diaphragm upper half is installed, and screw down joint surface bolts; or put

the diaphragm upper half into upper half casing, and screw down clamp plate.10

HP inner casing upper half & diaphragm carrier upper half installation:

Clean the upper half, particularly the supporting parts of diaphragm.

Clean up bolt electric-heating hole and all joint surface bolts; spread high-temperature

resisting lubricant on the thread part.

Clean upper-half nozzle block.

Install guide post and joint surface bolts.

Spread joint-face coating material on joint surface flange. (Appendix 3)

Install the upper half, however, casing combination requirements must be followed when the

casings are combined.

Clean up & inspect nuts and washers.


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3-14-3

According to requirements, screw down joint surface bolts. (including cold screw-down and

hot screw-down) See Drawing 3-14-1.

11

Gland seal upper half installation:

11.1Clean gland seal upper half, and check the gland seal teeth to see whether or not they are

awry.

11.2 Clean up bolt、nut and washeres, etc., supply the thread parts with lubricant.

11.3 Screw down joint surface bolts and drive in locating pins.

12 LP inner casing upper half installation:

12.1 Clean the upper half, especially the supporting parts of diaphragm.

12.2 Clean up all joint surface bolts & thread parts, spread high-temperature resisting lubricant

on the thread parts, and blow clean spray pipe & sprayer.

12.3 Clean up & inspect nuts and washers; assemble & spot-weld the sprayer firmly on the

turning seats.

12.4 Install guide post and joint surface bolts.

12.5 Lift flat LP inner casing upper half. By using the guide posts, slowly down the LP inner

casing upper half close to the lower half, and meanwhile, the overall joint surface flange

distances of upper & lower half shall be in agreement with each other. When the distances

between upper half flange and lower half flange are 500mm or so, joint-face coating

material should be spread on horizontal joint surface flange.

12.6 After LP inner casing upper half is in place, drive in locating pin, and screw down joint

surface bolts according to requirements, see Drawing 3-14-2; after all bolts are assembled,

be sure to inspect the joint surface flange through manhole to see whether or not there

appears any gape.

12.7 Be certain that no tools have dropped into the manhole, and install all manhole covers in

place.

13 HP & IP outer casing upper half installation:

Clean the upper half, especially the supporting parts of diaphragm carrier.

Clean up outer casing top key.

Clean up all joint surface bolts, spread high-temperature resisting lubricant on the thread

part.


Install guide posts and joint surface bolts.

Lift flat HP & IP outer casing upper half. By using the guide posts, slowly down HP & IPouter casing upper half close to the lower half, and meanwhile, the overall joint surface flange

distances of upper & lower half shall be in agreement with each other. When the distances

between upper half flange and lower half flange are closer, joint-face coating material shall be

spread on joint surface flange.

After HP & IP outer casing upper half is in place, screw down joint surface bolts according

to requirements (including cold screw-down and hot screw-down). See Drawing 3-14-3.

Check the HP & IP outer casing top key to see whether or not it is assembled according to

the drawing requirements.

14 LP outer casing upper half & LP-end gland seal upper half installation:

Clean the upper half, clean up all joint surface bolts & thread parts, and spread lubricant on


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3-14-4

the thread parts.


By using the guide post, slowly down the LP outer casing upper half close to the lower half,

and meanwhile, the overall joint surface flange distances of upper & lower half shall be in

agreement with each other; when the distances between upper half flange and lower half flange

are closer, joint-face coating material shall be spread on horizontal joint surface flange.

After LP outer casing upper half is in place, screw down joint surface bolts according to

requirements, see Drawing 3-14-4.

Screw down the joint surface bolts of end gland seal.

Drawing 3-14-1 HP inner casing joint surface bolt arrangement plan


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3-14-5

Note: M 76、M100 and M120 bolts shall be screwed down in a cold state in the order of the serial

numbers in this drawing, and then be screwed down in a hot state; for the force moment of cold

screw-down and the elongation (outer corner) of hot screw-down, please see《Bolt Hot

Screw-down Instruction Manual》.When casing is detached, loosen the bolts in the opposite order

to this drawing.

Drawing 3-14-2 LP inner casing joint surface bolt arrangement plan

Note: The bolts are symmetrical with steam turbine center line, and cold screw-down shall be

conducted in the order of the serial numbers in this drawing. When loosened, the bolts shall be

loosened in the opposite order of the serial numbers. The bolt specification is M48×3, and the

force moment of cold screw-down is based on Section 4-3 in the Instruction Manual.


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3-14-6

Drawing 3-14-3 HP & IP outer casing joint surface bolt arrangement plan

Note: M76 & M100 bolts fastening falls into two steps: cold screw-down goes first, and then, hot

screw-down moves ahead; the fastening shall be conducted in the order of the serial numbers in

this drawing. For the force moment of cold screw-down and the elongation (outer corner) of hot

screw-down, please see《Bolt Hot Screw-down Instruction Manual》.Please see Section 4-3 for

the fastening requirements of M48 bolt. When loosened, heat them according to the specified

values in the《Bolt Hot Screw-down Instruction Manual》, and loosen the bolts in the opposite

order of the serial numbers in this drawing.


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3-14-7

Drawing 3-14-4 LP outer casing joint surface bolt arrangement plan

Note: The bolts are symmetrical with steam turbine center line, and cold screw-down shall be

conducted in the order of the serial numbers in this drawing. When loosened, the bolts shall be

loosened in the opposite order of the serial numbers, and the force moment of the cold

screw-down is based on Section 4-3 in the instruction manual.


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3-15-1

3-15 Foundation back grouting

Secondary pouring may go ahead after the steam turbine and generator are already installed,

anchor bolts are screwed down, the spot welding of blocking iron is over, the dead-point locating

pin is in place, and each pipeline groove passing through secondary pouring layer is already laid.

Before pouring is underway, the foundation concrete and each base frame along front bearing

box side & LP casing side should be carefully cleared & cleaned so that there is no foreign object

and paint & oil stains.

Before pouring is underway, water should be sprinkled on the parts to be poured to a satisfactory

wet degree, and the pouring should go ahead continuously; in consideration of the pouring

difficulty inside the base frame, pouring must be done carefully to ensure that the internal space

of the base frame is solidly filled.

Before the concrete strength of foundation secondary pouring layer is not up to 50% of the

designed intensity, it is not permitted to disassemble & assemble heavy parts and conduct

percussion work on the unit; before it is not up to 80% of the designed intensity, it is not

permitted to re-assemble the anchor bolts and start up the unit.


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3-16-1

3-16 Couple connection

When the inter-connection work of all steam turbine & generator rotors is conducted, lube

oil should be supplied to every bearing of the steam turbine & generator, and the intensity of

back grouting layer shall be above 70%. When couplings are centered, the utmost efforts must be

made to achieve minimum center errors between them, and then, plug & screw down coupling

bolts. The working procedures are as follows:

1 Preparation work:

Clean up bolt holes、 bolts、nuts and washers, etc.;

Inspect the bolt hole numbers of two couplings to see whether or not they correspond with

each other, to make sure that there is any reaming margin in each bolt hole of two couplings.

2 Single rotor inspection: Re-check the jump values of coupling excircle and bearing journal.

3 Coupling centring measurement:

Please see the Certificate for each coupling centring requirements. When measured each

time, two-half couplings should first rotate 900

After Item 3.1 is confirmed up to standard, screw down technological bolts, make sure that

two couples have no possibility of moving towards each other when the couple bolt holes are

reamed, and the fastening technological bolts should be screwed down across corners;

simultaneously in the same direction; when the

rotor is turned, the measuring point position of two-half couplings should be aligned &

unchanged, and the turning angle should also be accurate & conformable.

The excircle run-out of the rotor couplings should be measured before & after with

technological joint bolts, and the variation values of each measuring point is not more than

0.02mm.

4 Coupling bolt preparations:

Measure bolt hole diameter and bolt length;

Make counter-balance inspections on the bolts, and on the condition that the bolt diameters

are the same, it is required that the total weight differences of two bolts in symmetrical positions

(together with the nuts、washers、cover plates and screws) be not more than 7g; when necessary,

the non-fit excircle section of the bolts may be turned for reducing weight, and the turning depth

is less than 2mm.

5 Reaming & bolt connection:

First select two holes with minimum reaming margins and ream them, insert two coupling

bolts which are formally fitted, turn the rotor, and ream other bolt holes one by one

symmetrically. In the process of boring or reaming, the two formal bolts shall not be extracted;When reamed, the hole roundness and verticality should be ensured. The reaming work of

each hole must be completed once and for all.

In the whole process of reaming, it is not permitted to conduct any work that may affect the

coupling center change, such as large-scale watering condenser, and connecting casing pipelines,

etc.;

Fit bolt external diameter according to bolt hole diameter, compile bolt serial numbers in the

order of hole numbers, and plug bolts in accordance with their numbers;

Before bolts are screwed down, special tools shall be used to measured the bolt length, and

then, screw them down pursuant to the specified bolt elongation data and make a record.


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3-16-2

Screwing down the bolts must be done one by one symmetrically;

After bolts are screwed down, each coupling bolt should be locked tight to prevent looseness.

6

Final inspection:

Re-inspect the peripheral jump of couplings, and compare it with the measurement prior to

connection. The variation value should not exceed 0.02mm, and meanwhile, inspect the bearing

journal jump;

Final record.

7 Installation orders:

HP & IP rotor is connected with LP rotor, and the LP rotor is connected with generator rotor.

8 Remove the false liner used for installation.


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3-17-1

3-17 Steam turbine auxiliaries installation

Steam turbine auxiliaries include main oil pump、atmosphere valve、turning gear 、cross-over

pipe and admission pipe, etc, which play a im

(wbb)d155a-000105asm - turbine installation manual

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