A Bansod Maintenance Manual For Kwu Turbine

MAINTENANCE MANUAL FOR KWU TURBINE
DR. ATUL BANSOD, Ph.D. (Maint. Management, Turbine Overhaul)

PURPOSE OF THIS MANUAL
The purpose of this manual is to provide guidance to carry out

overhauling activities. This manual is applicable to steam turbine of
various rating like 210, 250 & 500MW (KWU). The focus of this
manual is on detailing & description of various overhaul activities
along with standardization of scope of work for Capital & Annual
Overhaul. This also includes detail information which is required to
carry out commissioning of steam turbines after Overhaul. Although
this guidance does not establish absolute standards, but will
definitely help to establish and promote uniform practices and
provide performance guidelines.
In addition, formats for various activities including measurements

are standardized and formats of records are covered in this manual.
Every effort has been made to make each turbine maintenance

activity simple & reliable, supported with photographs.
Plant employees shall take responsibility of safety of machine &

health of workers during overhaul and maintenance activity.
This manual is one of the resources available for maintenance

personnel to utilize and apply their professional knowledge and
skills to establish benchmarks.
Dr. Atul Bansod, Ph.D.
FOREWORD
(Maint. Management, Turbine Overhaul)
FOREWORD
ABBREVIATIONS AND ACCRONYMS
HPT High Pressure Turbine

IPT Intermediate Pressure Turbine
LPT Low Pressure Turbine
CRO Couple Runout Check
FRO Free Runout Check
HPF High Pressure Turbine Front
HPR High Pressure Turbine Rear
IPF Intermediate Turbine Front
IPR Intermediate Turbine Rear
LPF Low Pressure Turbine Front
LPR Low Pressure Turbine Rear
HPF(R) High Pressure Turbine Front Right
HPF(L) High Pressure Turbine Front Left
IPF(R) Intermediate Pressure Turbine Front Right
IPF(L) Intermediate Pressure Turbine Front Left
LPF(R) Low Pressure Turbine Front Right
LPF(L) Low Pressure Turbine Front Left
Gen F Generator Front
Gen R Generator Right
Gen F(R) Generator Front Right
Gen F(L) Generator Front Left
Gen R(R) Generator Rear Right
Gen R(L) Generator Rear Left
OEM Original Equipment Manufacturer
TE Turbine End
EE Exciter End
TG Turbine Generator
PMG Permanent Magnet Generator
Note: Standing in front of front bearing pedestal, whatever is in front is front (F), accordingly
Right (R) & Left (L)
INDEX
PREPARATION AND PRECAUTIONS----------------------------------------------------------------------------------------------------------------- 1
CHAPTER I - OPERATING PARAMETERS OF 210/250/500 MW KWU TURBINE--------------------------------------------------------------3
1.1 - OPERATING PARAMETERS OF 210/250/500 MW KWU TURBINE----------------------------------------------------------------- 4
1.2 - TURBOVISORY READING------------------------------------------------------------------------------------------------------------------ 4
1.3 - TURBINE METAL TEMPERATURE-------------------------------------------------------------------------------------------------------- 5
1.4 - LUB OIL SYSTEM PARAMETERS-------------------------------------------------------------------------------------------------------- 5
1.5 - CW SYSTEM PARAMETERS---------------------------------------------------------------------------------------------------------------5
1.6 - AUXILIARY STEAM SYSTEM PARAMETERS-------------------------------------------------------------------------------------------6
1.7 - CONDENSATE EXTRACTION PUMP------------------------------------------------------------------------------------------------------6
1.8 - MAIN EJECTOR AND GSC------------------------------------------------------------------------------------------------------------------6
1.9 - CONDENSATE CYCLE-----------------------------------------------------------------------------------------------------------------------7
1.10 - BOILER FEED PUMP---------------------------------------------------------------------------------------------------------------------- 7
1.11 - FEEDWATER CYCLE----------------------------------------------------------------------------------------------------------------------- 8
1.12 - BEARING METAL TEMPERATURE------------------------------------------------------------------------------------------------------ 8
1.13 - BEARING VIBRATION---------------------------------------------------------------------------------------------------------------------9
1.14 - CONTROL ROOM VIBRATION---------------------------------------------------------------------------------------------------------- 9
1.15 - JACKING OIL PRESSURE---------------------------------------------------------------------------------------------------------------- 10
1.16 - VACUUM PUMP PERFORMANCE-----------------------------------------------------------------------------------------------------10
1.17 - GOVERNING SYSTEM------------------------------------------------------------------------------------------------------------------- 10
1.18 - GENERATOR PARAMETERS------------------------------------------------------------------------------------------------------------11
1.19 - BEARING VIBRATION READINGS----------------------------------------------------------------------------------------------------- 12
1.20 - LIST OF (SPECIAL) TOOLS REQUIRED FOR OVERHAULING OF TURBINE-------------------------------------------------------13
General------------------------------------------------------------------------------------------------------------------------------------- 13
Front Rearing Pedestal------------------------------------------------------------------------------------------------------------------ 13
Bearing No. 2 & 3 Pedestal------------------------------------------------------------------------------------------------------------- 13
Bearing No. 4 & 5 Pedestal------------------------------------------------------------------------------------------------------------- 13
Bearing No. 6------------------------------------------------------------------------------------------------------------------------------ 13
Bearing No. 7 Pedestal-------------------------------------------------------------------------------------------------------------------13
LP Casing----------------------------------------------------------------------------------------------------------------------------------- 14
IP Casing------------------------------------------------------------------------------------------------------------------------------------ 14
HP Casing`----------------------------------------------------------------------------------------------------------------------------------14
1.21 - TYPICAL SPARES RECOMMENDED FOR READY STOCK FOR OVERHAUL--------------------------------------------------- 15
1.22 - CONSUMABLES FOR 210 MW TURBINE DURING OVERHAUL------------------------------------------------------------------ 16
1.23 - SEALING & ANTISIEZING COMPOUNDS---------------------------------------------------------------------------------------------17
1.24 - RECOMMENDED MANPOWER REQUIRED FOR OVERHAUL---------------------------------------------------------------------18
CHAPTER II - SCOPE OF WORK IN ANNUAL AND CAPITAL OVERHAUL---------------------------------------------------------------------- 19
2.1 - SCOPE OF WORK IN ANNUAL AND CAPITAL OVERHAUL------------------------------------------------------------------------- 20
2.2 - OVERHAULING OF LPT------------------------------------------------------------------------------------------------------------------- 24
2.3 - OVERHAULING OF HYDRAULICALLY OPERATED VALVES OF TURBINE, LPBP SPRAY INJECTION VALVES ALONGWITH
THEIR ACTUATORS------------------------------------------------------------------------------------------------------------------------------25
2.4 - OVERHAULING OF CRH NRV------------------------------------------------------------------------------------------------------------26
2.5 - OVERHAULING OF HP BYPSS MAIN VALVES & SPRAY VALVES BPE1, BPE2, BD VALVES (WITHOUT SEAT CUTTING)-- 26
2.6 - SCOPE OF WORK FOR OH OF HRH STRAINER--------------------------------------------------------------------------------------- 26
2.7 - SCOPE OF WORK FOR OH OF MS STRAINER----------------------------------------------------------------------------------------- 27
2.8 - OH OF GENERATOR---------------------------------------------------------------------------------------------------------------------- 27
2.8.1 - Russian design Generator :-----------------------------------------------------------------------------------------------------27
2.8.2 - SIEMENS DESIGN GENERATOR WITH EXCITER :---------------------------------------------------------------------------- 29
2.9 - ASSISTANCE DURING MPI & NFT OF LPT ROTOR FREE STANDING BLADES 2X2 STAGES (OPTIONAL WORK)----------- 31
2.10 - ELECTRICAL/ DIGNOSTIC TESTS ON TURBINE, GENERATOR, AND NFT, MPI OF TURBINE BLADES ETC.---------------- 32
CHAPTER III - SYSTEMATIC PROCEDURE OF TURBINE OVERHAULING---------------------------------------------------------------------- 34
3.1 - OVERHAULING OF KWU TURBINE----------------------------------------------------------------------------------------------------- 35
3.2 - ACTIVITIES LIST FOR OVERHAULING OF HP MODULE------------------------------------------------------------------------------35
3.3 - DECOUPLING OF ROTOR AND AXIAL POSITIONING-------------------------------------------------------------------------------- 36
3.4 - BREACH NUT OPENING------------------------------------------------------------------------------------------------------------------37
3.5 - LIFTING OF HP MODULE-----------------------------------------------------------------------------------------------------------------37
3.6 - REMOVAL OF FRONT AND REAR GLAND BOX COVER----------------------------------------------------------------------------- 37
3.7 - REMOVAL OF GLAND SEAL SEGMENTS (HP FRONT)------------------------------------------------------------------------------- 38
3.8 - MAKING MODULE VERTICAL-----------------------------------------------------------------------------------------------------------38
3.9 - REMOVAL OF THREADED RING OR LOCKING SEGMENTS------------------------------------------------------------------------- 39
3.10 - LIFTING OF INNER CASING------------------------------------------------------------------------------------------------------------ 39
3.11 - BOX UP OF HP CASING----------------------------------------------------------------------------------------------------------------- 40
3.12 - ACTIVITY LIST FOR OVERHAULING OF IP MODULE------------------------------------------------------------------------------- 41
3.13 - ACTIVITY LIST FOR OVERHAULING OF LP TURBINE------------------------------------------------------------------------------- 42
3.14 - ALIGNMENT OF HP, IP AND LP ROTORS-------------------------------------------------------------------------------------------- 43
3.15 -ROLE-PLAYED BY SHAFT DEFLECTION CURVE IN ALIGNMENT OPERATION---------------------------------------------------44
3.16 - COUPLING CHECK----------------------------------------------------------------------------------------------------------------------- 45
3.17 - ALIGNMENT PROCEDURE------------------------------------------------------------------------------------------------------------- 46
3.18 - RUNOUT CHECK------------------------------------------------------------------------------------------------------------------------- 47
3.19 - COUPLING-------------------------------------------------------------------------------------------------------------------------------- 47
3.20 - REVISIONING OF COMBINED JOURNAL & THRUST BEARING------------------------------------------------------------------- 48
3.21 - BLUE MATCHING OF THRUST BEARING---------------------------------------------------------------------------------------------49
3.22 - BEARING REVISIONING---------------------------------------------------------------------------------------------------------------- 49
3.23 - OIL FLUSHING AND PEDESTAL BOX UP----------------------------------------------------------------------------------------------50
3.24 - BUMP CHECK---------------------------------------------------------------------------------------------------------------------------- 51
3.25 - HORN DROP TEST----------------------------------------------------------------------------------------------------------------------- 52
3.26 - ROLL CHECK------------------------------------------------------------------------------------------------------------------------------ 52
3.27 - SWING CHECK--------------------------------------------------------------------------------------------------------------------------- 54
CHAPTER IV - TURBINE COMMISSIONING-------------------------------------------------------------------------------------------------------- 55
4.1 - OIL FLUSHING----------------------------------------------------------------------------------------------------------------------------- 56
4.2 - COMMISSIONING OF GOVERNING SYSTEM----------------------------------------------------------------------------------------- 57
4.3 - COMMISSIONING OF HP BYPASS SYSTEM------------------------------------------------------------------------------------------- 59
4.4 - COMMISSIONING OF LP BYPASS SYSTEM-------------------------------------------------------------------------------------------- 59
4.5 - COMMISSIONING OF SEAL OIL SYSTEM---------------------------------------------------------------------------------------------- 60
4.6 - ROLLING OF TURBINEGENERAL CONDITION---------------------------------------------------------------------------------------- 61
4.7 - HYDRAULIC ROLLING---------------------------------------------------------------------------------------------------------------------62
4.8 - TURBINE START UP CURVES------------------------------------------------------------------------------------------------------------ 64
CHAPTER V - HP TURBINE PHOTOGRAPHS------------------------------------------------------------------------------------------------------- 70
5.1 - LIFTING HP MODULE---------------------------------------------------------------------------------------------------------------------71
5.2 - PLACING ON STAND AT UNLOADING BAY------------------------------------------------------------------------------------------- 71
5.3 - FRONT END OF CASING------------------------------------------------------------------------------------------------------------------72
5.4 - REAR END OF CASING--------------------------------------------------------------------------------------------------------------------72
5.5 - ARRANGEMENT OF HPT COMPLETE ROLL CHECK---------------------------------------------------------------------------------- 73
5.6 - ROLL CHECK OF HP CASING-------------------------------------------------------------------------------------------------------------73
5.7 - FITTING OF ROLL CHECK DEVICE-------------------------------------------------------------------------------------------------------74
5.8 - REMOVAL OF HP REAR SEALS---------------------------------------------------------------------------------------------------------- 74
5.9 - CASING VERTICAL FIXTURE------------------------------------------------------------------------------------------------------------- 75
5.10 - ASSEMBLY OF RADIAL LOCK BEFORE MAKING CASING VERTICAL------------------------------------------------------------- 75
5.11 - ASSEMBLY OF RADIAL LOCK AT FRONT END COMPLETE------------------------------------------------------------------------ 76
5.12 - MAKING MODULE VERTICAL----------------------------------------------------------------------------------------------------------76
5.13 - JACKING ARRENGEMENT OF INNER CASING---------------------------------------------------------------------------------------77
5.14 - ARRANGEMENT OF HYDRAULIC JACKS--------------------------------------------------------------------------------------------- 77
5.15 - FITTING PIN BEFORE TILTING HPT INNER CASING ON STAND------------------------------------------------------------------ 78
5.16 - INNER CASING LOCKING/THREADED RING REMOVED-------------------------------------------------------------------------- 78
5.17 - LOCKING SEGMENTS------------------------------------------------------------------------------------------------------------------- 79
5.18 - VALVES------------------------------------------------------------------------------------------------------------------------------------ 79
5.19 - INNER CASING ADDITIONAL JACKING ARRANGEMENT-------------------------------------------------------------------------- 80
5.20 - INNER CASING AND ROTOR RADIAL LOCK ARRANGEMENT---------------------------------------------------------------------81
5.21 - LIFTING INNER CASING FROM OUTER CASING------------------------------------------------------------------------------------ 81
5.22 - PLACING INNER CASING ON HORIZONTAL FIXTURE------------------------------------------------------------------------------82
5.23 - HP TURBINE INNER CASING----------------------------------------------------------------------------------------------------------- 85
5.24 - INTERNALS------------------------------------------------------------------------------------------------------------------------------- 86
5.25 - HPT FRONT GLAND BUSH------------------------------------------------------------------------------------------------------------- 86
5.26 - HPT ROTOR-------------------------------------------------------------------------------------------------------------------------------87
5.27 - HPT INNER CASING--------------------------------------------------------------------------------------------------------------------- 87
CHAPTER VI - HP MODULE DOCUMENTS--------------------------------------------------------------------------------------------------------- 89
6.1 - HP TURBINE – INNER CASING (PARTING PLANE GAP)----------------------------------------------------------------------------- 90
6.2 - HP TURBINE – INNER CASING (OVALITY MEASUREMENT)----------------------------------------------------------------------- 91
6.3 - RADIAL CLEARANCES AT GUIDE BLADES OF HP TURBINE ------------------------------------------------------------------------ 92
6.4 - RADIAL CLEARANCES AT MOVING BLADES OF HP TURBINE----------------------------------------------------------------------93
6.5 - AXIAL CLEARANCES BETWEEN BLADES OF HP TURBINE --------------------------------------------------------------------------94
6.6 - AXIAL CLEARANCES BETWEEN BLADES OF HP TURBINE --------------------------------------------------------------------------95
6.7 - AXIAL SEAL STRIP CLEARANCES OF MOVING BLADES OF HPT------------------------------------------------------------------- 96
6.8 - AXIAL SEAL STRIP CLEARANCES OF GUIDE BLADES OF HP TURBINE------------------------------------------------------------ 98
6.9 - HP SHAFT SEALING RADIAL AND AXIAL CLEARANCES(FRONT)----------------------------------------------------------------- 99
6.10 - HP SHAFT SEALING (REAR) TS (ASSEMBLY) RADIAL AND AXIAL CLEARANCES--------------------------------------------- 103
6.11 - HP SHAFT SEALING ASSEMBLY------------------------------------------------------------------------------------------------------ 105
6.12 - HP SHAFT BEARING REAR (ASSEMBLY)-------------------------------------------------------------------------------------------- 106
6.13 - MINIMUM RADIAL CLEARANCE IN THE BLADE SECTION OF HP TURBINE (ASSEMBLY)---------------------------------- 107
6.14 - MINIMUM AXIAL CLEARANCES WITHOUT SHAFT SEAL (BUMP CHECK)---------------------------------------------------- 108
6.15 - HP CASING ASSEMBLY JOINT FLANGE BOLTS – TIGHTENING & ELONGATION---------------------------------------------109
6.16 - ELONGATION OF BOLTS (HPC EXHAUST ELBOWS)------------------------------------------------------------------------------ 110
6.17 - HP CASING ASSEMBLY---------------------------------------------------------------------------------------------------------------- 111
6.18 - ASSEMBLY DIMENSIONS AT THE CASING----------------------------------------------------------------------------------------- 115
6.19 - HP TURBINE ASSEMBLY REFERENCE DIMENSIONS------------------------------------------------------------------------------116
6.20 - H. P. INLET INSERT ASSY. (ASSEMBLY)---------------------------------------------------------------------------------------------117
CHAPTER VII - IP MODULE ASSEMBLY DOCUMENTS------------------------------------------------------------------------------------------118
7.1 - IP TURBINE – INNER CASING (PARTING PLANE GAP)-----------------------------------------------------------------------------119
7.2 - IP TURBINE – INNER CASING (OVALITY MEASUREMENT)----------------------------------------------------------------------- 120
7.3 - RADIAL CLEARANCES AT GUIDE BLADES OF IP TURBINE (TS)------------------------------------------------------------------- 121
7.4 - RADIAL CLEARANCES AT GUIDE BLADES OF IP TURBINE (GENERATOR SIDE)------------------------------------------------122
7.5 - AXIAL CLEARANCES BETWEEN BLADES OF IP TURBINE LOWER HALF (TURBINE SIDE)-------------------------------------123
7.6 - AXIAL CLEARANCES BETWEEN BLADES OF IP TURBINE LOWER HALF(GENERATOR SIDE)---------------------------------124
7.7 - AXIAL SEAL STRIP CLEARANCES OF MOVING BLADES OF IPT------------------------------------------------------------------- 125
7.8 - IP SHAFT SEALING RADIAL AND AXIAL CLEARANCES (TURBINE SIDE)---------------------------------------------------------127
7.9 - IP SHAFT SEALING RADIAL AND AXIAL CLEARANCES (GENERATOR SIDE)---------------------------------------------------- 130
7.10 - IP SHAFT SEALING (ASSEMBLY)----------------------------------------------------------------------------------------------------- 132
7.11 - MINIMUM RADIAL CLEARANCE IN THE BLADE SECTION OF IP TURBINE (ASSEMBLY)----------------------------------- 134
7.12 - MINIMUM AXIAL CLEARANCES AT THE SEALING STRIPS OF THE GUIDE BLADES----------------------------------------- 135
7.13 - IP CASING ASSEMBLY JOINT FLANGE BOLTS – TIGHTENING & ELONGATIONOBSERVED VALUES----------------------136
7.14 - BOLTTIGHTNING OF IP CASING (OUTER)------------------------------------------------------------------------------------------137
7.15 - IP CASING ASSEMBLY CLEARANCE MEASUREMENT (GENERATOR SIDE)--------------------------------------------------- 138
7.16 - IP CASING ASSEMBLY CLEARANCE MEASUREMENT (TURBINE SIDE)-------------------------------------------------------- 139
7.17 - IP CASING ASSEMBLY CLEARANCE MEASUREMENT---------------------------------------------------------------------------- 140
CHAPTER VIII - DOCUMENTS FOR GENERAL OVERHAUL------------------------------------------------------------------------------------- 141
8.1 - LP AXIAL BLADE CLEARANCES-------------------------------------------------------------------------------------------------------- 142
8.2 - LP RADIAL BLADE CLEARANCES------------------------------------------------------------------------------------------------------143
8.3 - SEAL BORE READING------------------------------------------------------------------------------------------------------------------- 144
8.4 - LP ROTOR AXIAL LOCATION----------------------------------------------------------------------------------------------------------- 145
8.5 - MAIN OIL PUMP ASSEMBLY CLEARANCES (ASSY)---------------------------------------------------------------------------------147
8.6 - MAIN OIL PUMP :SHAFT CONCENTRICITY CHECK---------------------------------------------------------------------------------148
8.7 -MAIN OIL PUMP :COUPLING CLEARANCES-----------------------------------------------------------------------------------------148
8.8 - HYDRAULIC TURNING GEAR NOZLE BOX RADIAL AND AXIAL CLEARANCES--------------------------------------------------149
8.9 - CLEARANCES OF BEARING SEAL STRIP---------------------------------------------------------------------------------------------- 150
8.10 - CLEARANCES Of OIL GUARD RING AT BEARING---------------------------------------------------------------------------------151
8.11 - BEARING CLEARANCES--------------------------------------------------------------------------------------------------------------- 152
8.12 - RADIAL THRUST BEARING------------------------------------------------------------------------------------------------------------153
8.13 - SWING CHECK-------------------------------------------------------------------------------------------------------------------------- 154
8.14 - ALIGNMENT---------------------------------------------------------------------------------------------------------------------------- 155
8.15 - HP/IP JOURNAL AND COUPLING RUN - OUT------------------------------------------------------------------------------------ 156
8.16 - IP/LP JOURNAL AND COUPLING RUN - OUT------------------------------------------------------------------------------------- 157
8.17 - LP/GEN. JOURNAL AND COUPLING RUN OUT------------------------------------------------------------------------------------158
8.18 - HP ROTOR FLOAT AND ROLLING TEST---------------------------------------------------------------------------------------------160
8.19 - IP ROTOR FLOAT AND ROLLING TEST---------------------------------------------------------------------------------------------- 161
8.20 - LP ROTOR FLOAT AND ROLLING TEST--------------------------------------------------------------------------------------------- 162
8.21 - HORN DROP TEST----------------------------------------------------------------------------------------------------------------------163
8.22 - CLAMPING BLOCKS CLEARANCES-------------------------------------------------------------------------------------------------- 164
8.23 - HP ROTOR STUB SHAFT RUN OUT------------------------------------------------------------------------------------------------- 165
8.24 - JACKING OIL LIFT AT JOURNAL AND PRESSURE----------------------------------------------------------------------------------166
8.25 - PEDESTAL L- CLAMP CLEARANCES-------------------------------------------------------------------------------------------------167
8.26 - HP CASING AXIAL REFERENCE-------------------------------------------------------------------------------------------------------168
8.27 - IP CASING AXIAL REFERENCE--------------------------------------------------------------------------------------------------------169
8.28 - PROTECTIVE DEVICE CLEARANCES------------------------------------------------------------------------------------------------- 170
8.29 - HP STUB SHAFT RUN OUT-----------------------------------------------------------------------------------------------------------171
8.30 - JACKING OIL LEFT AT JOURNALS AND PRESSURE--------------------------------------------------------------------------------172
CHAPTER IX - VALVES AND GOVERNING-------------------------------------------------------------------------------------------------------- 174
9.1 - HP STOP & CONTROL VALVES CLEARANCES---------------------------------------------------------------------------------------175
9.2 - IP STOP & CONTROL VALVES CLEARANCES---------------------------------------------------------------------------------------- 176
9.3 - LP BYPASS STOP &CONTROL VALVES CLEARANCES------------------------------------------------------------------------------177
REFERENCES------------------------------------------------------------------------------------------------------------------------------------------ 178
PREPARATION AND PRECAUTIONS
Before taking up the actual overhauling it is necessary to know the condition

of the unit so as to assess the quantum of work during the overhaul and planning
can be done accordingly. Prior to start the overhauling, the following information
must be collected well in advance.
1) Study the operational data and collect the details about the outages during the
preceding year analyze the data and highlight the causes of the outages along
with the measure to overcome them. All the defects which need rectification
are enlisted.
2) Make a complete list of works to be done and fit them in time bound schedule.
3) Insure the availability and condition of all the special tools and tackles supplied
with the turbine by the OEM.
4) Ensure that the consumables required are available in the store.
5) Ensure the availability of mandatory and essential spares.
6) For reference ensure availability of all the relevant drawings of the turbine and
associated systems.
7) To avoid hazards to personnel and equipment the isolation of the equipment
should be checked very carefully prior to the start of work. All the inlet and
outlet valves should be closed and drain valves if any should be opened. A
protocol must be signed on this account between the operation engineers and
maintenance engineers before the unit is handed over for maintenance.
8) Ensure the availability of all cranes, lifting devices, to avoid accidents or
serious damage to the plant. All lifting devices should be tested and comply
with the station safety regulation.
9) Suitable storage bins should be available to ensure the safe storage of small
components.
10) Suitable tags should be available to facilitate the identification of the bolts.
Nuts, studs, pipes etc. to avoid intermixing.
11) Quick drying paints of various colors as per color code should be available
to color the items as and where necessary.
12) Suitable supports, stands, racks and frames should be readily available. A
positioning layout also should be prepared for the heavy and large
components of the turbine. It is essential to facilitate the proper placement of
heavy components on suitable supports.
13) Delicate and fragile parts, which are not be dismantled such as gauges,
thermocouples, transducers, impulse piping etc. should be properly protected
against damage.
1
14) Wooden blank flanges to fit inside the opening of the pipes, cylinders or
pedestals must be put and tied in position to prevent ingress of any foreign
material.
15) Stands for keeping the HP, IP and LP rotors must be available and checked
before using the same.
16) Care should be taken to avoid oil spillage on the floor or area around the
equipment.
17) Firefighting equipment and first aid boxes should be available near the
work site.
18) Temporary office along with telephone facilities on job site should be
installed to avoid delays in communication.
19) A cleaning gang should continuously work to keep TG floor area free to
dust, dirt, rags, paper etc.
2
CHAPTER I - OPERATING
PARAMETERS OF 210/250/500
MW KWU TURBINE
3
OPERATING PARAMETERS OF 210/250/500 MW KWU TURBINE
1.1 - OPERATING PARAMETERS OF 210/250/500 MW KWU TURBINE

(To be collected before and after overhaul)
S.NO. DESCRIPTION UNITS VALUE
1. Load MW
2. Frequency / Speed Hz / RPM
3. Main steam pressure Kg/cm2
4. Main steam temperature C
0
5. MS flow TPH
6. CRH steam pressure Kg/cm2
7. CRH steam temperature C
0
8. HRH steam pressure Kg/cm2

9. HRH steam temperature C
0
10. Ist Stage Pressure Kg/cm2

11. LP Exhaust hood temperature C
0
12. Condenser Vacuum Kg/cm2
1.2 - TURBOVISORY READING

1. Axial shift mm
2. HP Differential expansion mm
3. IP Differential expansion mm
4. LP Differential expansion mm
5. IP overall expansion mm
6. HP overall expansion mm
4
1.3 - TURBINE METAL TEMPERATURE

1. ESV Ti/Tm C
0
2. IV Ti/Tm C
0
3. HP Casing metal Ti/Tm C

0
4. IP Casing metal Ti.Tm C

0
5. HP Shaft Ti/Tm C
0
6. IP Shaft Ti/Tm C
0
7. HP Top / Bottom Temperature C

0
8. IP Top / Bottom Temperature C

0
1.4 - LUB OIL SYSTEM PARAMETERS

1. Lub oil header pressure Kg/cm2
2. Lub oil temperature before cooler C
0
3. Lub oil temperature after cooler C

0
4. MOP suction / discharge pressure Kg/cm2
1.5 - CW SYSTEM PARAMETERS
1. Condenser CW water inlet temperature C

0
2. Condenser CW water outlet temperature C

0
3. Condenser CW water inlet pressure Kg/cm2
4. Condenser CW water outlet pressure Kg/cm2
5
1.6 - AUXILIARY STEAM SYSTEM PARAMETERS

1. Gland steam pressure Kg/cm2
2. Gland steam temperature 0

C
3. Gland steam / Leak off steam controller position %

4. Auxiliary steam pressure Kg/cm2
5. Auxiliary steam temperature 0

C
6. Steam Pr. To Main Ejector (in case ME is there) Kg/cm2
7. Steam temperature to ME (in case ME is there) 0

C
8. IP Top / Bottom Temperature 0
C
REGENERATIVE CYCLE PARAMETER
1.7 - CONDENSATE EXTRACTION PUMP
1. Hotwell temperature 0
C
2. CEP discharge header pressure Kg/cm2
3. CEP discharge header temperature 0

C
4. CEP A/B/C Current Amp
5. Condensate flow TPH
1.8 - MAIN EJECTOR AND GSC

1. ME inlet temperature (if ME exist) 0
C
2. ME steam pressure (if ME exist) Kg/cm2
3. ME steam temperature (if ME exist) 0
C
4. GSC inlet temperature 0
C
6
1.9 - CONDENSATE CYCLE

1. Drain cooler inlet temperature 0
C
2. LPH-1 inlet temperature 0
C
C
C
5. LPH-3 outlet temperature 0
C
6. LPH-1 drip temperature 0
C
C
C
9. Extraction no. 1 pressure Kg/cm2
10. Extraction no. 1 temperature 0
C
C
C
15. D/A pressure Kg/cm2
16. D/A temperature 0
C
C
1.10 - BOILER FEED PUMP

1. BFP A / B / C suction pressure Kg/cm2
2. BFP A / B/ C suction temperature 0
C
3. BFP A / B / C discharge temperature 0
C
4. BFP A / B/ C discharge pressure Kg/cm2
5. BFP A / B/ C motor current Amp
6. Feed water flow TPH
7
1.11 - FEEDWATER CYCLE

1. HPH-5 inlet temperature C
0
2. HPH-5 outlet temperature C

0
3. HPH-6 outlet temperature C

0
4. HPH-5 drip temperature C

0
5. HPH-6 drip temperature C

0

7. Extraction no. 5 temperature C
0

9. Extraction no. 6 temperature C
0
1.12 - BEARING METAL TEMPERATURE
Units Metal temperature Drain oil temperature
TL TR BL BR
Bearing no. 1 0
C
Bearing no. 2 0
C
Thrust bearing 0
C
Bottom Front Bottom Rear
Bearing no. 3 0
C
Bearing no. 4 0
C
Bearing no. 5 0
C
Bearing no. 6 0
C
Bearing no. 7 0
C
8
1.13 - BEARING VIBRATION

INSTRUMENT USED:-
H V A
DISP VEL DISP VEL DISP VEL
UNITS µ, pk-pk mm/s, 0-pk µ, pk-pk mm/s,0-pk µ, pk-pk mm/s, o-pk
Bearing no. 1
Bearing no. 2
Bearing no. 3
Bearing no. 4
Bearing no. 5
Bearing no. 6
Bearing no. 7
1.14 - CONTROL ROOM VIBRATION

ABSOLUTE SHAFT VIB. BEARING VIBRATION
X Y V H
UNITS µm, pk-pk
BEARING NO. 1
BEARING NO. 2
BEARING NO. 3
BEARING NO. 4
BEARING NO. 5
BEARING NO. 6
BEARING NO. 7
9
1.15 - JACKING OIL PRESSURE
DESCRIPTION UNITS VALUE

Bearing no. 1 Kg/cm2
1.16 - VACUUM PUMP PERFORMANCE
Vacuum pump seal inlet / outlet temp. C

0
CW inlet / outlet temp. C

0
Air & vapour temperature C

0
Rotameter reading Kg/Hr
1.17 - GOVERNING SYSTEM

Control oil pressure Kg/cm2
Trip oil pressure Kg/cm2
Auxiliary secondary oil pressure Kg/cm2
HP secondary oil pressure Kg/cm2
IP secondary oil pressure Kg/cm2
Primary oil pressure Kg/cm2
HPCV 1 / 2 position %
IPCV 1 / 2 position %
Speeder gear / EHC position %
10
1.18 - GENERATOR PARAMETERS

Reactive Power Mvar
Power factor cos Ø
Generator field voltage Volts
Generator field current Amps
Rotor temperature 0C
Generator winding temperature 0C
Generator Current 0C
Generator Voltage KV
Cold gas temperature 0C
Hot gas temperature 0C
DP (Seal oil – H2 pressure) Kg/cm2
Hydrogen purity %
Stator water flow m3/hr
11
1.19 - BEARING VIBRATION READINGS

UNIT# Rating
Date: Time: Load : Frequency : MVar :

MST MSP HRHT HRHP LP Exh Vacuum
SPEED O/A Vel O/A Displ PHASE ANGLE Others Frequecies Remarks
Brg. RPM mm/sec,pk Microns, p-p 1X- 2X-
1H
1V
1A
2H
2V
2A
3H
3V
3A
4H
4V
4A
5H
5V
5A
6H
6V
6A
7H
7V
7A
12
1.20 - LIST OF (SPECIAL) TOOLS REQUIRED FOR OVERHAULING OF

TURBINE
General
1) Lifting Device for HP Rotor.
2) Lifting Device for IP Rotor.
3) Lifting Device for LP Rotor.
4) Rotor Lifting and Adjusting Device (for HP, IP and LP).
Front Rearing Pedestal

1) Foundation Bolts – 105 mm (Hammering Spanner)
2) Pedestal Sole Plate Bolts – 115 mm.
3) Pedestal P/P Bolts – 14 mm Allen Key.
4) Pedestal Inspection cover – 6 mm Allen Key.
5) Pedestal “Z” Clamps – 75 mm Hammering Spanner.
6) Casing to Pedestal clamps – 55 mm Hammering Spanner.
Bearing No. 2 & 3 Pedestal

1) Pedestal P/P Bolts – 14 MM Allen Key.
2) Casing to Pedestal Clamps – 55 mm Hammering Spanner.
3) Inspection cover – 6 mm Allen Key.
4) Pedestal “Z” clamps – 75 mm Hammering Spanner.
Bearing No. 4 & 5 Pedestal

1) Foundation Bolts – 95 mm Hammering Spanner.
2) Pedestal parting plane – 14 mm Allen Key.
3) LPT Compensator Below (P/P) – 46 mm.
Bearing No. 6
1) Foundation Bolts – 95 mm hammering Spanner.
2) Pedestal Parting Plane – 75 mm Hammering Spanner.
Bearing No. 7 Pedestal

1) Sole plate to Pedestal – 55 mm Hammering Spanner.
2) Foundation Bolts – 46 mm Hammering Spanner.
3) Parting Plane – 46 mm.
13
LP Casing
1) LP Outer Casing P/P Bolts -65 & 36 mm Hammering Spanner.
2) LPT Exhaust Diaphragm 24/26 Ring Spanner.
3) LP Sole Plane to Foundation – 85 mm Hammering Spanner.
4) IP Inner Casing P/P bolts -41 mm Hammering Spanner.
5) LP Casing Inner Outer Jack Bolts (For Roll Check) – 41 mm Hammering Spanner.
6) LP Outer Cover Jack Bolts M-36-41 mm Hammering Spanner.
IP Casing
1) IP Outer Casing Cap Nut -75, 85 and 95 mm Hammering Spanner.
2) IP Inner Casing Cap Nut -105 and 120 mm.
3) IP Casing Jack Bolts (for Roll Check ) M64- 50 MM Hammering spanner.
4) IP Inner Casing Jack Bolts (For Roll check) M-36 – 50 MM.
HP Casing`
1) HP Casing gland box (R) – 41 mm Hammering spanner.
2) HP Casing gland box (L) – 27 mm Ring Spanner.
3) HP Exhaust Elbow Flange – 65 mm Hammering Spanner.
4) HP Inner Casing P/P – 75 mm Hammering spanner.
5) HP Casing insert – 50 mm Hammering spanner.
6) HP Casing Jack Bolts (For Roll Check) M -64 – 56 mm
7) HP Inner Casing P/P Jack bolts M-36 – 41 mm Hammering Spanner.
8) HP/IP Coupling – 65 mm Box Spanner.
9) LP/IP Coupling – 70 mm.
10) LP / GEN – 55 mm.
11) Pedestal No. 1 Jack Bolts M-50 – 65 mm Hammering Spanner.
12) Pedestal No. 2 jack Bolts M- 65 – 55 MM.
13) Coupling jack bolts 50 & 46 mm.
14) Jacking Oil line – 36 / 32 , 41 mm – Single Head.
14
1.21 - TYPICAL SPARES RECOMMENDED FOR READY STOCK FOR

OVERHAUL
1) Coupling Bolts for L.P – Generator, IP –LP and HP-IP Coupling.

2) Thrust Pads for bearing no 2
3) MOP Thrust Bearing / Redial Bearing.
4) Control Valve studs HP/IP.
5) Control valves Nuts HP / IP.
6) HP & IP Control valve gland packing.
7) Seal Labyrinth side holding screws.
8) HPC & IPC Studs.
9) Labyrinth Seal for gland box.
10) Helical Springs for above seal Labyrinth.
11) Lock Washers for Labyrinth seals.
12) Brass Fins for HP, IP & LP Front / Rear oil guards.
13) LP Bypass stop valves studs / Nuts.
14) LP Bypass control valves studs / nuts.
15) Gland packing for LP bypass stop and control valves.
16) ESV / IV Servomotor ‘O’ ring.
17) Casing Radial and Axial Keys (for HP, IP and LP).
18) Jacking hose for Bearing no 1-7
15
1.22 - CONSUMABLES FOR 210 MW TURBINE DURING OVERHAUL
1) Oxygen Cylinders.
2) Acetylene.
3) Sleeper 25 x 250 x 2000.
4) Kerosene/Diesel.
5) Cotton waste.
6) Gland Packing ( Graphs, asbestos, Metalic)
7) Emery Paper 200 x 300 mm (36, 60 and 80, 100, 120, 180).
8) Hacksaw Blades (Size ½” and 1”)
9) Holdite
10) Rubber gasket (3 mm, 5mm )
11) Rustoline.
12) Oil sealent
13) Wooden Planks.
14) Diamond Lapping Paste (Medium).
15) Oil Paper (0.5 mm)
16) Prussian Blue.
17) Electrodes 680, Φ 2.5 mm.

18) Over chords Welding Rods.
19) MS Bolts AND Nuts.
20) Molycote. For 100 degree
21) Grinding Compound.
22) DP Test – Developer, Cleaner, Penetrant.
23) Feviquick.
24) Turbine Oil
25) Lead wire.
26) Polythene Paper.
27) Torch light.
28) Hand Lamp 24 V.
29) Wire Brushes.
30) Oil Can (1/2 liter, 1 liter, 5 liter.
31) Petrol.
32) Emery Cloth (Different Sizes).
33) Oil Stone.
34) Doctor’s / Medical Kit.
16
35) Shims (Different Sizes)

36) Drill Bits (5 mm to 10 mm)
37) Lead Wire (Φ = 1 mm).

38) Grease.
39) White Paint with small brushes.
40) Grinding Wheels (Deferent Sizes 4” to 10”)
41) Grinding Stones.
42) Circular Wire Brushes.
1.23 - SEALING & ANTISIEZING COMPOUNDS
S.NO LOCATION FEATURES RECOMMENDED

COMPOUND
01 JOINT PLANE OF HPT IPT & VALVE METAL TO METAL JOINT IN  BIRKOSIT
CASINGS, GLAND BOXES & HIGH TEMPERATURE ZONE  STAG B
STRAINER HOUSINGS, BREECH NUT
MATING FACE.  MAGNESITE COMPOUND OF BHEL
BHOPAL
02 JOINT PLANE OF LP OUTER CASING METAL TO METAL JOINT IN  HOLDITE
(WITHOUT RUBBER SEALING LOW TEMPERATURE ZONE  LOCTITE 574
CHORD).
03 JOINT PLANE OF BEARING METAL TO METAL JOINT IN  HYLOMER
PEDESTALS, MOP CASING, VALVE OIL ENVIRONMENT  GOLDEN HERMETITE
SERVOMOTOR.
 VICTOR SHELLAC
04 THREADED FASTNERS INCLUDING, HIGH TEMPERATURE  MOLYKOTE P37
BREECH NUT THREADS, KEYS, ( < 350c) ANTISIEZING  OKS 255
PACKERS, DOWEL PINS U & I - SEAL
RINGS IN HIGH TEMPERATURE
ZONE.
05 THREADED FASTNERS, KEYS,  MOLYKOTE D 21
PACKERS, DOWEL PINS IN LOW LOW TEMPERATURE  OKS 511
TEMP. ZONE, COUPLING BOLTS SEAL
( < 350c) ANTISIEZING  MGS 400
SEGMENTS, HP/IP CASING PALM
PACKERS, HP FRONT & REAR
BEARING PEDESTAL PACKERS
(OTHER THAN SELF LUBRICATED
LUBRITE PACKERS).
17
1.24 - RECOMMENDED MANPOWER REQUIRED FOR OVERHAUL
MANPOWER NUMBER DAYS
1. Incharge 1 76 days
2. Engineer 1 76 days
3. Supervisors 3 76 days
4. Technicians. (Total ) 1000 man days
5. Riggers. (Total ) 500 man days
6. Labors – Skilled (Total ) 500 man days
7. Labors – Unskilled (Total ) 1000 man days
18
CHAPTER II - SCOPE OF WORK
IN ANNUAL AND CAPITAL
OVERHAUL
19
SCOPE OF WORK IN ANNUAL AND CAPITAL OVERHAUL
2.1 - SCOPE OF WORK IN ANNUAL AND CAPITAL OVERHAUL

COH OF HP/IP/LPT, ALL VALVES AND STRAINERS INCLUDING GENERAL OH OF TURBINE.
SCHEDULE 1 : ALIGNMENT, ROLLING CHECKS, CASINGS CENTERING ETC.
1. Removal of turbine cladding as required.

2. Removal of pedestal covers and bearing halves of bearing no. 1 to 7.
3. Recording of deck spring heights and locking of deck springs as applicable.
4. Coupled run out checks of all rotor & couplings and swing check of rotor at HP front.
5. Decoupling of HP-IP, IP-LP, LP-GEN and HP-MOP couplings.
6. Removal of LP outer casing upper half.
7. Free run out and alignment checks on all rotors, journals and couplings as per requirement and
8. matching / scraping etc. on journals and coupling halves as per requirement and to the extent possible.
9. Ultrasonic and DP testing of bearings 1 to 7 and repair/replacement as per requirement..
10. Checking of bearing clearances and rectification by scraping, matching or replacement of bearing / liner to
the extent possible and as per requirement. Supervision and assistance in machining of bearing or bearing
liner as required during replacement.
11. Checking facial run out of HP and IP Rotor coupling faces and scraping, blue matching as required to correct
the run out. Alignment of HP-IP, IP-LP, LP-Generator, HP-MOP. This will include adjustment in packers,
bearing pedestals, bearing supports, lubrication of packers, keys their blue matching as per requirement.
Alignment correction of LP-GEN. to be carried out by adjusting / shifting Generator Stator / Rotor etc.Rolling
checks and required casing centering for HP, IP and LP Turbines which include adjustment, replacement of
casing keys, their blue matching , lubrication etc. Record Bump check of HP and IP Rotors and necessary
adjustment within available clearance.
12. Adjustment/centering of LP gland boxes as per recommended clearances including removal and refitting of
LP gland boxes for seat cutting / replacement as required.
13. Box up of LP outer casing.
14. Horn Drop checks of HP and IP casing and rectification by Shims / Packers as required.
15. Resetting of all bearings, oil seals and pedestal oil guard rings including repair/replacement of strips as per
requirement. Refitting of all bearings and setting of bearing pads & keys etc. as per requirement.
16. Servicing of over speed trip and thrust bearing trip devices including adjustment / repair / replacement if any.
Inspection of LPT Extraction Bellows.
17. MOP overhauling, this includes repair/replacement of components as per requirement and alignment etc.
18. Recording of values and releasing of deck springs as applicable.
19. Coupling of HP-MOP, HP-IP, IP-LP, LP- Generator, Reaming, Honing of coupling holes as per requirement.
20. Swing check of HP Front Rotor and necessary matching etc. in coupling as per requirement.
21. Rotor float and thrust pad check of thrust bearing and repair/replacement if any.
20
22. Barring gear nozzle inspection, repair / replacement of fins and resetting as per requirement.
23. Box up of all bearings and pedestals. Cleaning of rack filters and basket strainers during oil flushing as per
requirement. During Oil flushing will be as per quality of the oil in the circuit.
24. Assistance during commissioning.
25. Checking, adjustment and minor repair of all MS & HRH lines, CRH lines hangers.
26. Fitting of turbine cladding removed for O/H.
SCHEDULE – 2 : OVERHAULING OF HP TURBINE MODULE :
1.Removal of HPT insulation.

2.HPT Roll check and recording casing centre.
3.Removal of HPT rear bearing and placing back in position without thrust pads.
4.HPT Bump check.
5.Loosening or cutting of HPT inlet breech nuts, opening of exhaust elbows and gland steam pipe lines.
Cutting, re-welding including stress relieving & radiography of M.S lines as may be necessary.
6.Cutting of associated pipe lines such as drains, impulse lines etc.
7.Preparation for lifting of HPT Module.
8.Lifting of complete HP Module from pedestal and placing on stand.
9.Dismantling of HPT rear gland box, removal of front glands, recording roll check and bump check values at
every state, removal of inserts.
10. Locking of HPT rotor in the casing.
11. Tilting of complete module and placing in vertical position.
12. Removal of threaded ring from barrel recording key clearances.
13. Removal of rotor with inner casing from barrel with the help of attachments etc. and placing on the
same on fixture in horizontal position and inspection and cleaning of “U” seal ring and “I” seal ring also
repair / replacement as required.
14. Removal of HPT inner casing parting plane studs. For this, Induction heating machine shall be arranged
by BHEL. However, the subcontractor shall provide all assistance from
15. Loading/unloading of the equipment, opening of casings and closing, etc. All manpower required for
the same including rigging gangs and helpers and T&P shall be provided by the subcontractor.
16. Removal of top half inner casing and recording flow path reading.
17. Lifting of HPT Rotor and removal seal segments from casing halves.
18. Alumina/ sand blasting of HPT Rotor, inner casing halves and other components.
19. Inspection, repair of casing / rotor fins, gland fins.
20. Length measurement and DPT of HPT inner casing parting plane studs and replacement as required.
21. HPT inner casing and inlet assembly “U” seal ring pre-compression check, DPT, visual inspection /
replacement before assembly.
21
22. Placement of top half on bottom half and checking of parting plane gap and ovality before and after
heat tightening the studs.
23. Checking of inner casing centering w.r.t. barrel with dummy shaft and finalizing radial key sizes.
24. Place HPT Rotor over the inverted upper half casing and record all axial and radial clearance.
25. Fixing of sealing segments and placement of HPT Rotor.
26. Recording flow path reading and assembly with upper half inner casing. Repeat with bottom half.
27. Heat tightening of inner casing parting plane studs.
28. Roll check and bump check of HP Rotor with inner casing and centering.
29. Locking of inner casing with rotor.
30. Insertion of HP Rotor with inner casing into barrel.
31. Fitting of casing keys, threaded ring or lock ring as applicable.
32. Making HPT Module Horizontal.
33. Fixing of gland box and seal segments, recording roll check and bump check at every stage.
34. Lifting of HPT Module land placement on TG Pedestal & subsequent loading to bearings.
35. HPT Roll check and Bump check.
36. HPT horn drop checking and correction.
37. HPT inlet breech nuts & exhaust elbows connection along with associated pipe lines.
SCHEDULE – 3 : OVERHAULING IP TURBINE MDOULE :
1. Removal of complete insulation of IP Turbine and dismantling of associated and required piping. Checking
of axial and radial clearances in the assembled condition after noting down the control dimensions.
2. Removal of gland box seals on both sides, checking of axial and radial clearances and repair/replacement
of any components of gland boxes, as per requirement. Loosening of outer casing parting plane bolts and
removal of the top half casing. For this Induction heating machine shall be arranged by BHEL. However,
the subcontractor shall provide
3. All assistance from loading/unloading of the equipment, opening of casings and closing, etc.
4. All manpower required for the same including rigging gangs and helpers and T&P shall be provided by the
subcontractor.
5. Rolling test and float test of IP rotor with respect to inner casing after centering the casing.
6. Loosening of inner casing parting plane bolts and removal of top half of casing. For this, Induction heating
machine shall be arranged by BHEL. However, the subcontractor shall provide all assistance from
loading/unloading of the equipment, opening of casings and closing, etc.
7. All manpower required for the same including rigging gangs and helpers and T&P shall be provided by the
subcontractor.
22
8. Measurement of flow path clearances, and necessary replacement/repair of fins of rotor and casing as per
requirement.
9. Measurements of parting plane stud lengths, testing and replacement as per requirement.
10. Removal of Rotor.
11. Facial run out checks on HP coupling half, IP coupling halves and LP coupling halves and necessary
scraping / matching to the extent possible as required.
12. Casing parting plane ovality check and necessary correction on casing parting plane for minimum contact
of 10 mm from the stud hole.
13. Removal of inner bottom casing if required.
14. Cleaning by alumina /sand blasting of inner casing and Rotor, inspection of seal strips of the inner casings
and repair / replacement of fins, as per requirement.
15. Placement of top half of inner casing / outer casing (without rotor ) on bottom half for checking ovality of
casing after tightening of the parting plane studs. Ensure that L-Rings are made free.
16. Removal of casing top half after checking the ovality of the casing.
17. Placement of rotor in the ZERO position in the inner casing and necessary grinding/machining of casing
and rotor fins etc. and adjustment in keys, packers etc. as per requirement during checking of axial /radial
clearances of blades/fins.
18. Final box up of inner casing after thorough cleaning, checking for minimum axial and radial clearances by
rolling checks, bump check, horn drop check of inner casing and necessary rectification as per
requirement.
19. Checking for axial and radial clearances of seal strips of sealing segments of the outer casing (both top and
bottom half) and necessary adjustment/grinding as per requirement.
20. Placing of top half of IP outer casing on the bottom half after cleaning and boxing up of the outer casing.
21. Checking of the axial / radial clearances of seal strips and boxing up of gland boxes after necessary
grinding etc. as per requirement.
22. Final checking of axial / radial clearances in the assembled condition and necessary rectification as per
requirement.
23. Final connection of associated piping etc.
24. Assistance for removal and replacement of IPT thermocouples and putting new ones as per instruction
and requirement of C&I.
23
2.2 - OVERHAULING OF LPT
1. Carrying out dismantling roll check of Inner-outer casing.

2. Supporting of LP Inner outer casing bottom after roll check of inner outer casing.
3. Removal of top half of inner-outer casing after loosing of parting plane bolts.
4. Carrying out dismantling roll check of Inner-Inner casing.
5. Opening of inner-inner outer casing parting plane bolts and lifting of inner –inner top half.
6. Recording of relevant axial and redial clearances at parting plane.
7. Removal of Front and rear gland boxes.
8. Removal of LP Turbine rotor and placing on support.
9. Cleaning of LPT Rotor and Inner-inner casing (Alumina/Sand blasting as required.)
10. Cleaning of Inner-inner casing bottom half using emery paper (as required)
11. Ovality check of inner-inner casing with and without tightening of parting plane bolts.
12. Inspection of last stage blades, internals of steam space like compensator bellows wherever visible,
circular supports etc. any repair/replacement as per requirement.
13. Removal of top half of front and rear gland boxes, inspection of sealing strips of both halves and rotor
along with adjustment in Gland box keys as per requirement.
14. Rolling check of LP Turbine along with necessary adjustments in keys, lubrite plate etc. as per requirement.
15. Placing of rotor in LPT inner-inner casing Bottom half & recording of clearances.
16. Assembly of front and rear gland boxes.
17. Placing of LPT inner-inner top half and box up of both halves.
18. Placing of LPT Inner-outer casing top-half in position.
19. Tightening of parting plane bolts of Inner-outer casing.
20. Roll check of LPT assembly with Inner-outer casing in boxed up condition.
Carry out necessary alignment of casing, as required. Replacement of eroded balancing weights.
24
2.3 - OVERHAULING OF HYDRAULICALLY OPERATED VALVES OF

TURBINE, LPBP SPRAY INJECTION VALVES ALONGWITH THEIR
ACTUATORS
HP STOP & CONTROL VALVES, IP STOP & CONTROL VALVES ,LP BYPASS STOP & CONTROL VALVES, LP BYPASS
WATER INJECTION VALVES:
1. Before dismantling of the stop and control valve governing characteristics of stop/control valves should
be taken and any discrepancy on the valve side should be attended during overhaul.
2. Erect scaffolding at valves as required and remove insulation.
3. Removal of measuring instruments. Take reference dimensions.
4. Drain actuator housing. Remove oil lines and steam leak off line.
5. Heat and remove valve body cover bolts.
6. Disassemble valve completely.
7. Open coupling between valve and servomotor.
a. Detach actuator housing from valve body cover.
b. Dismantling of servomotor internals and cleaning of all internals.
c. Carry out DPT as per requirement.
d. Disassemble actuator and valve completely.
8. Complete revision of the servomotor, replacement/repair of components, as required.
9. Determine condition of valve and decide on maintenance work to be attended. Carry out DP Test of valve
internals (body, seat, disc., spindle etc.) as per requirement.
10. Clean and de-scale component parts.
11. Inspect valve stem and pilot disc. Check stem for run out. Carry out DP test of valve internals (body, seat,
disc, spindle etc.) as per requirement. Inspect sealing faces at the valve seat and disc. Lap up if necessary.
12. Check clearances and install the actuator and valve body.
13. Inspect pistons springs, discs and sealing faces.
14. Reseal and assemble actuator.
15. Attach actuator and valve body cover to valve body and heat bolts. Connect up stem.
16. Associate with BHEL/CUSTOMER during installation of measuring instruments and indicators of the valves.
Start oil pumps and check valves for leak and proper functioning. Attend the defects.
17. After completion of the job governing characteristics should be set as per standard values in association
with BHEL/CUSTOMER.
18. Do hot tightening of valve flanges, glands and bonnets at part load and full load of machine.
25
2.4 - OVERHAULING OF CRH NRV

1. Making necessary scaffolding and approach platform for CRH NRV.
2. Removal of existing insulation cladding sheet and insulation in the top cover area of NRV.
3. Removal of oil pipe line from NRV servomotor, Decoupling of servomotor from valve spindle and removal
of servomotor from position.
4. Opening the top cover of CRH NRV by making proper lifting arrangement and removal of all internals like
flap, spindle etc.
5. Cleaning of all internals including pressure seal area and checking for any erosion mark in gasket seating
areas. Carry out DPT as per requirement.
6. Repair and replacement of defective component.
7. Build up and repair of eroded portion by grinding and matching.
8. Box up of NRV with new pressure seal gasket/components.
9. Tightening of the cover to the required torque and hot tightening of the same after charging.
10. Fixing the servomotor in position, Coupling the servomotor with NRV spindle and fixing of oil pipes of
servomotor
11. Attending to leakages if any after charging.
12. Removal of temporary platforms and scaffoldings.
2.5 - OVERHAULING OF HP BYPSS MAIN VALVES & SPRAY VALVES

BPE1, BPE2, BD VALVES (WITHOUT SEAT CUTTING)
1. Decoupling and removal of actuators as may be required.

2. Dismantling of valves.
3. Cleaning / checking/ DP/ ultrasonic Testing of valve components and repair to the extent possible at site.
4. Lapping of seats and disc.
5. Assembly of valves.
6. Placement and coupling of actuators.
7. Assistance for commissioning of valves.
2.6 - SCOPE OF WORK FOR OH OF HRH STRAINER
1. Cutting of Strainer drain pipe.

2. Removal of Strainer, Repair / Replacement of Strainer as per requirement.
3. Cleaning of components, inspection, DPT of components, Repair of weld joint of element with blanking
plate.
4. Assembly of Strainer.
5. Welding of drain pipes and DP Test of weld joints
26
2.7 - SCOPE OF WORK FOR OH OF MS STRAINER
1. Cutting of Strainer drain pipe.

2. Removal of Strainer, Repair / Replacement of Strainer as per requirement.
3. Cleaning of components, inspection, DPT of components, Repair of weld joint of element with blanking
plate.
4. Assembly of Strainer.
5. Welding of drain pipes and DP test of weld joints
2.8 - OH OF GENERATOR
2.8.1 - Russian design Generator :

1. Conducting Air Tightness Test on entire Generator and its pipe lines and other components of gas system.
2. Removal, dismantling and cleaning of all four gas coolers, Hydraulic Test of each gas cooler and plugging
of leakage tubes as required.
3. Removal of Brush Gear cable and Brush gear assembly.
4. Removal of seal oil and Lub oil pipe lines.
5. CRO Readings to be taken. Decoupling of LP Gen. and taking alignment reading for reference, checking of
FRO.
6. Removal of TE and EE seal covers and seal body and seal rings.
7. Bearing no.5 and 6 top pedestal cover removal.
8. Bearing no.5 and 6 top and bottom half removal after checking the clearances of bearing as per BHEL
protocol. Replacement of Bearing no.5 and 6 as required.
9. Removal of Inner oil catcher at both ends.
10. Checking of pedestal insulation of Bearing no.6.
11. Checking of seal rings of EE and TE and replacing as required.
12. Removal of EE and TE End shields and Fan shields.
13. Measurement of Air gap and Magnetic Center as per BHEL protocol as necessary.
14. Removal of Bearing no.6 pedestal after giving support to the rotor.
15. Removal of rotor fan blades.
16. Threading out TG rotor and placing it on the stand.
17. Cleaning of stator, thorough inspection of stator, stator core, stator cooling gas circuit and hydrogen
cooler water pipes, stator overhang bracket bolts, core bar bolts and other fasteners inside the stator are
to be inspected for tightening and proper locking of nuts and bolts.
27
18. Inspection of stator and slot wedge, checking for tighten sand tightening of loose wedges by dewedging
and re-wedging by using suitable packers below the wedges, tightness mapping chart to be prepared
before and after carrying out actual wedge tightening work. Checking of looseness of braiding in overhang
portion.
19. Replacement of winding RTD’s as required.
20. Hydraulic testing of stator winding as per BHEL protocol and attending any leakages thereby in Teflon
tubes or copper pipes. In case of it requires removal of putty boxes, re-assembly of the boxes to be done.
21. Pneumatic testing of stator winding as per BHEL protocol.
22. Draining of stator water from the windings.
23. Assistance in Carrying out ELCID Test on the stator core & RSO test on rotor.
24. Measurement of PI value of stator and bringing it to a value more than 2 by Hot air blowing, as required.
25. Assistance in Tan Delta and Partial discharge test on the Generator to be carried out.
26. Carrying out Rotor Purge Test. Die Penetration test and UT of Rotor retaining rings after removal of Paint
in the retaining rings.
27. Die Penetration test of the Fan blades after removal of paint. DPT and UT of seal rings.
28. Conducting DP and Ultrasonic test of Bearing no. 5 and 6.
29. Heating the stator suitably, glue injector in the winding overhang portions as required.
30. Varnishing of stator winding after completion of work and drying out of varnish.
31. Blue matching of Bearing no.6 pedestal with foundation.
32. Blue matching of Bearing no.6 with pedestal and then with shaft journal.
33. Pedestal insulation checking and rectification if found less. Adjustment of oil catcher and deflector plate
as per BHEL protocol and replacement of fins of oil catcher as required. Cleaning of all lub oil and seal oil
pipe lines and seal body. DP test to be done on all welding joints of pipe lines. Air tightness test of Rotor
as per BHEL Protocol and if leakage is there rectification of the same by opening CC Bolts.
34. Taking rotor IR value and rectification of the same if found less. Replacement of CC bolt to be done as
required. Insertion of TG rotor inside stator.
35. Assembly of end shields and fan shields.
36. Assembly of seal rings, seal cover and seal body.
37. Assembly of bearing no.6 and its pedestal.
38. Assembly of seal oil and Lub oil lines at both ends after slope checking.
39. Alignment of LP-Generator and coupling of LP-Gen.
40. Assisting in assembly of Brush Gear and alignment of Brush Gear as per BHEL Protocol. Brush holder
adjustment.
41. Assisting in Brush Gear cable termination.
42. Assembly of Gas coolers.
43. Disconnection of Phase and neutral links from GT.
28
44. Cleaning of all impulse lines of Generator.

45. Cleaning of seal oil and stator water coolers and carrying out Hydraulic test of the same.
46. Plugging of the leaky tubes or replacement of cooler to be done.
47. Cleaning of filters of stator water system and seal oil system.
48. Cleaning of stator water magnetic filter.
49. Cleaning of expansion tank of stator water and replacement of gaskets as required.
50. All Gaskets, O rings and rubber cords to be replaced with new ones.
51. Gas Tightness checks and inspection of Phase and Neutral Bushing and Attending any leakage thereby.
Replacement of Gaskets/insulators of all the 9 nos. of bushings (as required). Thorough cleaning of phase
and neutral bushing area.
52. Commissioning of seal oil system and attending any leakages as required.
53. Generator air tightness checking as per BHEL Protocol & attending leakages.
54. Checking of stator water bushing and replacement of gaskets and O rings.
55. Taking final readings of CRO as per protocol.
56. Assisting in measurement of Rotor/Stator IR, PI, DC resistance & impedance values.
2.8.2 - SIEMENS DESIGN GENERATOR WITH EXCITER :

1. Dismantling and removal of Exciter. After swing check, decoupling and alignment checking.
2. Removal of Exciter/PMG Assy. from position
3. Dismantling and removal of Generator end shields, H2 coolers, seal assembly and pipe lines.
4. DP/UT of H2 seals liners and replacement of liner as required.
5. Dismantling and removal of bearing no.5, 6 & 7. Checking of insulation and replacement as required.
6. DP/UT of all Bearings
7. Threading out of Generator rotor & after completion of works thread –In
8. Inspection and cleaning of Generator stator/ rotor& Exciter/PMG
9. ELCID Test of Generator will be done by BHEL and all assistance including arrangement of cables, switch
boards, cut-outs etc. to be provided by the contractor.
10. Stator wedge tightness, Core looseness, overhang portion strengthening work, match joint spacer work
shall be carried out by BHEL and all assistance to be provided by the contractor
11. Checking /Revisioning of Diode wheel & replacement of fuses as required.
12. Physical checking of multi contact pins for healthiness.
13. Gas leak test of Generator Rotor & Exciter Rotor CC bolts and attending leakage by replacement of CC
bolts if required.
14. Stator winding cleaning by CTC before glue injection and varnishing. Required quantity of CTC and other
cleaning agent along with cloth to be arranged by contractor.
15. DP/UT checks of rotor retaining rings and fan blades. Assistance during various generator electrical tests.
29
16. Inspection & Replacement of all Terminal bushings along with gaskets. (6 Nos.)
17. UT check of Generator seal rings and replacement as required.
18. Dismantling/cleaning of H2 coolers ,exciter coolers, Hydraulic Test & attending leakage by plugging of
tubes
19. Glue injection and varnishing of stator wdg.
20. Varnishing of Gen. Rotor
21. Insertion of Generator Rotor and Boxing up of Generator.
22. Air tightness test of Generator casing at 4 kg/cm2 for 24 hrs.
23. Color matching of Generator bearing.
24. Replacement of oil catcher fins as necessary.
25. Replacement of any of defective components of Generator & Exciter and varnishing of same.
26. Checking of the Generator stator palms for any feeler gap.
27. Matching of exciter pedestal with the exciter base frame and revisioning of exciter bearing including
replacement as required. Re-matching of Exciter anchor plate and tightening of anchor bolts to required
elongation.
28. Revisioning of PMG Assembly, Varnishing and assembly
29. Assistance during the N.F.T of Generator end winding. & checking of terminal nose joint
30. Removal of Exciter dome, Stator top half & removal of rotor & complete overhauling
31. Revisioning of Exciter/PMG Assy. Assistance during testing, cleaning & varnishing
32. Swing check of exciter and necessary correction
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2.9 - ASSISTANCE DURING MPI & NFT OF LPT ROTOR FREE STANDING
BLADES 2X2 STAGES (OPTIONAL WORK)
1. Cutting of welding of locking plates of both sides of LPT Rotor free standing blades.
2. Removal of locking plates of both sides of blades.
3. Removal of all clamping pieces.
4. Removal of blades with proper marking.
5. Thorough cleaning of blades and their grooves in the rotor by suitable means so as to remove corrosion
products, if any.
6. Inspection of blades roots and their grooves in the rotor.
7. Crack detection of all blades by MPI (Coil method) -100%
8. Fitting of all blades (cleared by MPI) in the position with technological pieces.
9. Fitting of technological pieces in place of clamping pieces.
10. Measurement & recording of Natural Frequency of blades.
11. Removal of technological pieces.
12. Replacement of technological pieces by new clamping pieces.
13. Fitting of locking pieces in position.
14. Welding of locking plates as per drawing.
NOTE: If any defect is observed in blades then it is to be replaced by new one. If the natural frequency of any of the
blades is found to be beyond permissible range & it cannot be improved upon even after proper cleaning of the
blade root & its groove in the rotor, then the blade has to be replaced by new one.
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2.10 - ELECTRICAL/ DIGNOSTIC TESTS ON TURBINE, GENERATOR, AND

NFT, MPI OF TURBINE BLADES ETC.
Following tests to be carried out :
GENERATOR STATOR :
1. IR & PI Test with 5 KV megger.
2. DC winding resistance measurement.
3. Tan Delta/Power Factor/Capacitance test.
4. Computerized Digital ELCID test.
5. Partial Discharge probe test OR Offline PD Analysis.
6. DC leakage current/Step Voltage test.
7. Stator Slot wedge system check (wedge tightness mapping)
i) By Wedge deflection test if ripple springs are installed)
ii) By wedge knocking test.
8. RTD elements check.
9. IR with 1000V DC source and amp. Meter
GENERATOR ROTOR :
1. IR & PI
2. Digital RSO Test
3. AC Impedance measurement.
5. Diode wheel check.
6. Voltage balance test.
EXCITER :
1. IR & PI
3. Pole impedance test
4. Pole drop test.
GENERATOR :
1. NFT of Generator End Winding.
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TURBINE :
1. Natural frequency test on LP turbine rotor free standing blades of 120/200/210 & 250 MW sets.
2. Natural frequency test on LP turbine rotor free standing blades of 500 MW sets.
3. MPI of LP rotor blade roots, rotor grooves, rotor discs, rotor shaft etc.
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CHAPTER III - SYSTEMATIC
PROCEDURE OF TURBINE
OVERHAULING
34
SYSTEMATIC PROCEDURE OF TURBINE OVERHAULING
3.1 - OVERHAULING OF KWU TURBINE
PROCEDURE :
1) Before overhauling of turbine record all turbovisory parameters for reference.
2) Before stopping barring gear at HPC 350° temp., start removal of insulation from HP/IP module &
complete it till stopping of barring gear.
3) Note down governing & LPBP characteristics from rack with the help of starting and load limiting device.
4) Stop barring gear, stop AOP & JOP.
5) Start opening of all pedestals parting plane bolts.
6) Record seal bore readings at each pedestal, record yoke key clearances & removal yokes.
7) Record all reference readings of rotor with respect to pedestal, remove top half of bearings and note
down side oil, top oil clearances of all bearings.
8) Note down coupled run out of rotor at each journal & couplings with the help of dial gauge by mounting
dial on pedestal and pointer on journal and coupling.
9) Decouple LP / Generator coupling as per procedure & separate Generator from Turbine.
10) Carry out roll check, Bump Check, Horn drop check of casings as per set procedure & note down
readings for future correction.
11) Decouple HP/IP, IP/LP coupling as per procedure.
12) Open HP, IP, LP casing.
13) Measure the float of rotor with pads assembled in thrust bearing.
14) Before dismantling of bearings check bearing oil catcher clearances.
15) Ensure JOP operation from local, as it is required frequently for number of checks of turbine. If JOP is
not available ensure sufficient stock of thick oil for lubrication of rotor & pins required for rotor rotation
at all couplings.
3.2 - ACTIVITIES LIST FOR OVERHAULING OF HP MODULE

Removal of insulation from casing :
After shut down & during cooling down of turbine this activity can be carried out before stopping barring gear.
Ensure that MOT vapor exhaust fans made off; otherwise the insulation may be sucked from pedestal oil
guard & will enter into MOT.
Cutting of pipelines connected with HP casing :

1) Before cutting the pipelines properly put paint mark on each pipeline for identification.
2) Cut pipeline in such a way that it should be easy to re-weld.
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3) Immediately after cutting the pipelines close the open part of it with gaskets /wooden flange or polythene
sheet. This should not be neglected, as there is possibility that some body may put some foreign material
inside it & which will finally damage the turbine complete.
4) Before cutting of dismantling pipelines, these are to be locked with beam to avoid abnormal loading on
hangers. The locking is must for HP inlet & exhaust pipes.
Assembly of turning over device & HPT assembly fixture :

1) This is an independent activity & should be taken up before few days of withdrawal of unit.
2) All threads of base plate should be cleaned & many other supports are to be identified & assembled
together as per drawing supplied by manufacturer.
3) The frame of base plate should be grouted in such a way that the front side of casing will remain below
main hoist of EOT crane.
4) The base frame of casing support should be grouted in such way so that shortest arm of frame will remain
below main hoist of EOT crane.
5) During grouting of base frames of HP Casing support & Turning over device ensure the common center
line.
6) Grout the foundation bolts with quick setting cement & place only outer casing support stand in position.
7) After turning the casing on device, place it on casing support and change the fixture layout for placement
of HP inner casing.
3.3 - DECOUPLING OF ROTOR AND AXIAL POSITIONING
1) Before decoupling put JOP in service, unscrew all 16 Nos. of HP/IP coupling bolts. Take out four no of
opposite coupling bolts & replace it with loose (clearance) coupling bolts. One by one take out all bolts,
the bolts should come out with little tapping of copper bar.
2) The nuts and bolts should be stored carefully, protect it from damage on threads.
3) Put IP front rotor lifting device in position, load the device remove the loose coupling bolts.
4) Put guide pins in coupling holes to hold IP rotor in position to avoid sudden unloading of rotor from spigot.
5) HP Rotor is jacked towards front & removed from spigot.
6) Rotor is axially positioned on the basis of available reference reading of rotor thrust collar to casing spigot.
7) After positioning, rotor is locked axially with the help of axial lock.
8) Now once the rotor is lock axially, there are two alternatives to lock rotor radially. One is to support rotor
on HP front & rear rotor lifting device and another is to put radial lock plates in position before removal of
bottom bearings.
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3.4 - BREACH NUT OPENING
1) Before breach nut opening check the heating device for any sort of chocking of nozzles. This can be
removed with induction heater.
2) Check whether the gas regulators & gas supply pipes are in good working condition.
3) Make arrangement of two LPG cylinders per nut.
4) Assemble the device on Breach nut, with the help of jackscrew maintain equal gap between nozzle &
breach nut body face. Industrial gas torch can be used for heating if nozzle arrangement is not available.
5) Light up gas & slowly increase gas pressure with regulator. The pressure of both cylinders should be
increased equally so that uniform heating is obtained all over the face of nut.
6) Heat the nut up the temperature of 2000 C the required temperature can be checked by thermal chalk or
leaser thermometer. After attaining the temp close the gas supply & removal the device.
7) Put the nut rotating pin inside the hole provided on nut & rotate the nut in anti clockwise direction by
taking load on crane with the help of sling. Rotate the nut till it become free for manual rotation.
8) Take out nut & support it on wooden slippers, remove U-Seal ring & properly protect it from damage.
9) Removal of HP exhaust elbows where there are two exhaust pipes. In case of single exhaust HP turbine,
open exhaust flange provided at bottom of the casing.
3.5 - LIFTING OF HP MODULE
1) Before lifting the module ensure that all four pedestal clamps of HP casing are removed.
2) Check the availability of sling 2 Nos. 12 Mtr. x 60 mm.
3) Take out all radials & axial keys of casing, check that pipes below & above casing are cut & removed.
4) Lift the casing with the help of main hoist & check the level (by putting sprit level on journal).
5) Make the level of casing, lift it & place it on stands assembled in unloading bay.
3.6 - REMOVAL OF FRONT AND REAR GLAND BOX COVER

1) Opened all peripheral bolts at rear & front gland box cover, heating may be required while opening of
these bolts. The bolts are heated on its head & opened with the spanner of 36 mm. In case of any censure
it is advised to remove it by method of grousing.
2) Radial locking with inner casings: Before removing front rotor lifting device, put the radial locks in position.
This can be put in position by going inside through HP exhaust connection. The locks should be positioned
in such a way that there will not be any clearance i.e. 03 feeler thigh. So that inner casing is firmly
supported in outer casing.
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3) After putting these locks in position the front shaft lifting device can be removed. Now it is easy to
remove casing gland box covers. The gland box covers should be removed carefully without damaging
sealing segments & rotary seals. With the help supplied fixture.
4) Couple the casing turning device to rotor at rear end with Allen bolts M-30.
5) Assembly another support stand on base frame at casing rear end to support the rotor lifting device
assemble on casing turning device.
6) Temporarily shift the load of rotor on crane shift the rotor lifting device on coupled casing turning device
& remove rear- casing top & bottom gland box cover. After removal of rear gland box cover a radial lock
ring is put in position. Before putting this ring, rotor is centered axially as per reference readings.
7) After fixing radial lock ring in position, final axial lock- ring is fitted on this ring & rear shaft lifting device is
removed.
3.7 - REMOVAL OF GLAND SEAL SEGMENTS (HP FRONT)
1) For removal of these seals, manufacturer supplies a special fixture. The stationary bush is assembled on
journal no I & the rotary bush type turning fixture are assembled on stationary bush. There should be
sufficient clearance between stationary & rotary bush so that easy turning of rotary bush is possible.(not
applicable where gland bush complete is provided.)
2) Check tie rods for its threading, counter check with threading of seal segments. The threaded end is fitted
in segments & another end is locked in rotary bush.
3) Before removal of sealing segments, remove segment window cover. Put sufficient antirust liquid in seals
for easy removal.
4) Assemble the fixture & take out the seal segment by rotating rotary bush on fix / stationary bush with tie
rods. Move the segment in such a way that the compression spring comes in window, remove the spring
with special tool provided by manufacturer. Similarly remove all springs & finally take out the segment.
Repeat the same procedure for all three rows of sealing segments, (6 segments per row).
3.8 - MAKING MODULE VERTICAL
1) Before making module vertical ensure that outer casing supports are assembled properly in their
respective position to support outer casing on four places at front end.
2) With the help of main hoist and special D- shackle provided by manufacturer, make the casing vertical on
stand at its front end, lift it shift it to outer casing support stand.
3) Tight casing on stand with bolts size M-36 X 50.
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3.9 - REMOVAL OF THREADED RING OR LOCKING SEGMENTS
1) Remove threaded ring locks when the casing was horizontal on stand.
2) Assemble the beams 2 Nos. on casing rear top with the help of special long bolts (12 Nos) for pressing
inner casing down so that compression of U-seal is released & thread ring /sealing segments can be taken
out easily by rotating in anticlockwise direction.
3) Put two no hydraulic jack below the beam & press inner casing against outer cases about 0.1 to 0.3 mm.
4) Put the striker pieces in the slots provided on threaded ring, hammer the striker pieces at a time with two
persons in position till the ring is free to rotate in threads. Remove the beams & with the help of crane
rotate the threaded ring, lift it & place it on wooden slipper.
5) The next step is to remove radial keys provided for locking of inner to outer casing ( 8 from rear & 4 from
front). Before removing front keys remove lock plates & grub screws. The keys can be removed with the
help of puller and knocking ring arrangement.
6) Assemble the rotor guide bush on outer casing at front end to guide rotor while removing inner casing
from outer casing.
7) Before lifting inner casing change the fixture layout of base plat & put inner casing support stand &
journal support stand in position.
3.10 - LIFTING OF INNER CASING
1) Put two no of hydraulic jack below inner casing inside outer casing jack inner casing against outer casing
equally to release inner casing from I. seal ring. Mount dial gauge at top pointer on inner casing & base on
outer casting. Note the upward displacement of casing. Take load on crane & continue jacking till the
inner casing is free from I seal ring.
2) Lift the inner casing, take out from outer casing, and Put the pin (100 mm dia, 500 mm long) inside the
dummy assembled to the rear end. There is sufficient clearance in between pin & bush of assembled
dummy at rear end.
3) Rest the pin on stand & slowly make the casing horizontal, assemble the roller stand below journal No. 1,
2 & finally remove all radial, axial locks of casing & rotor.
4) Leveled the casing with the help of spirit level, center the rotor with respect to casing or casing with
respect to rotor by checking front exhaust side radial gap between rotor blades and casing.
5) After centering carry out roll check of inner casing. The rotor can be moved left / right, top / bottom with
the help of roller stand. Take all readings & start dismantling P/P bolts with the help of heating device or
induction heater provided by manufacturer.
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6) Remove the top half of the casing, inspect rotor & casing for any damage, measure the flow path
clearance with the help of filler gauge & outside micrometer. Measure the axial gap between rotary &
stationary sealing strips with the help of taper wedge.
7) If necessary measure rotor inter stage run out (if high vibrations are reported), for the measurement of
run out special dial gauge with spoke is used.
8) Lifting rotor & placing it on stand. The rotor is lifted with the help of rotor lifting beam, which has facility
to level the rotor in horizontal plane.
9) Clean the casing as well as all casing components completely. Assemble the top & bottom half & measure
the P/P(parting plane) gap & casing ovality. If required, remove the high spots of P/P with the help of
parallel block, again assemble the casing by hand tightening & measure the gap. The characteristics of gap
should be like this …that it is open inside & close towards outside from center of casing.
10) Repair of damage sealing segments: Removing damage strips, replacing with new strip & square wire can
be carried out to repair the segments. Replace the seal segment compression springs if necessary.
3.11 - BOX UP OF HP CASING
1) Assemble the seals in top & bottom half of inner casing, (Rear side) place rotor in position with journal
on roller support. Apply jointing compound on parting plane & place top half in position & box up the
casing with hot tightening. Before hot tightening measure the length of each stud for final
measurement of elongation after tightening.
2) The tightening toque is applied as per degree of rotation given in drawing. The same degree is marked
on circumference of the nut, then it is heated to particular temperature & cap nut is turned through as
per the marked distance. This gives correct tightening & required elongation of P/P studs. After cooling
measure the length of each stud to work out elongation. Elongation is nothing but it is difference
between cold stud length before hot tightening & length after hot tightening.
3) Align the rotor with roll & bump check: Assemble the radial & axial locks on casing, make it vertical &
insert it in outer casing. Before insertion check that the outer casing is properly cleaned & dress for
any damage place U – seal ring in position. Assemble threaded ring/sealing segments, make the casing
horizontal & place it on stand.
4) Box up front & rear seals & gland box. Align rotor with roll & bump check, put axial & radial locks in
position.
5) Lift the module & place it in position.
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3.12 - ACTIVITY LIST FOR OVERHAULING OF IP MODULE
1) Removal of insulation.
2) Before removal of any pipeline carry out Roll check & centering readings of casing.
3) Cutting of extraction pipe lines.
4) Removal of IP inlet pipe: Open both flange joints, if required use heating for opening of bolts. With the
help of auxiliary hoist of EOT crane & chain pulley block, perfectly balance the pipeline, lift the pipe line &
place it horizontally on wooden sleeper, protect insert from damage to its mating face.
5) Removal of seal steam inlet & leak off pipe lines.
6) Before opening P/P bolts of casing load the casing on jack bolts at all Four Corners of casing.
7) Removal of P/P Bolts with the help of heating device supplied with machine by manufacturer or by
induction heater. Number all studs & cap nuts & give same numbers to P/P holes so that the same stud
will go to its original position. Protect stud & cap nut from any damage.
8) Removal of top half of casing: Before removal of top half of casing tension both exhaust pipe lines with
the help of chain pulley block for easy removal of casing. Lift outer casing place it on wooden slipper.
9) Inspect the casing, remove eccentric bush from bottom side & carry out roll check & bump check with
inner casing.
10) Opening of P/P Cap nuts of inner casing with the help of heating device supplied with machine or
induction heater.
11) Removal of top half of inner casing & measurement of flow path readings, radial clearance between
stationary seals & rotor blades, measurement of axial clearance between stationary & rotary seals.
12) Removal of IP rotor : For removal of IP rotor, use rotor lifting device, level the rotor in zero-zero position
(parallel to axis of rotation) lift it slowly, avoid any jerk while lifting the rotor, place it on stand.
13) Inspect rotor & casing both for any damage. Clean rotor & casing both with cleaning agent & smooth
emery paper clean studs cap nut & other components of casing.
If inner casing bottom half is not lifted, then immediately cover the space in between inner &
outer casing with wooden covers, also cover extractions holes with dummies in order to protect entry of
foreign material inside the casing.
14) Replacement of damage sealing segments from stationary seal by new square wire, check the
compression of all springs, replace the spring with new spring if necessary.
15) Box up of casing :
a) Before box up removal all extraction covers & cover placed in between inner & outer casing, check for any
foreign material inside casing. Lift the rotor clean it with air & place it in position slowly, avoid jerk while
placing the rotor in order to avoid damage.
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b) Lift the top half of casing, clean the P/P with cleaning agent, slowly place it in the position, before placing
completely apply jointing compound (Stag.-B) in between parting plane. Place it completely & tighten it
with heat tightening device or induction heater, measure the elongation.
c) Carry out roll & bump check of inner casing, note down readings.
d) Lift outer casing, clean the P/P with cleaning agent, tension the cross around pipe lines with chain pulley,
and place the casing in position, see that the casing should seat easily without application of external
force. Put jointing compound in between P/P of outer casing. Put all four dowel pins in position, all studs
& cap nuts in position. Tighten the casing with heating device.
e) Assemble the inlet pipeline, tighten it properly. Re-weld the extraction pipe lines. Assemble leak off & seal
steam lines, replace joints (Gaskets) of all these lines including cross around lines. Remove the locks of
bellow of cross around pipelines & tighten the joints.
f) Measure the elongation of all studs, carry out roll & bump check of complete IP casing. Take the centering
reading and prepare the final radial & axial keys.
3.13 - ACTIVITY LIST FOR OVERHAULING OF LP TURBINE
1) Removal of LP top cover & putting checker plates on opened part of condenser.
2) Carry out roll check of complete casing.
3) Lift top half of LP inner outer, inner-inner casing & gland box. Before lifting inner outer casting open the
inspection windows & take out locks & eccentric bush.
4) Check flow path clearances with feeler gauge & outside micrometer.
5) Put LP rotor Compensator support fixture in position or both ends LP front & rear, as these are lifted with rotor.
6) Lift the rotor with rotor lifting device & place it on stand.
7) Inspect the casing internally, check rotor for any damage or serious erosion. Clean the casing & rotor
mechanically with emery paper.
8) If necessary carry out fins cutting & grinding wherever clearances are reduced as per readings obtained in roll
check of inner-outer & inner-inner casing.
Box up of casing:
A) Clean the rotor fully with sand blasting, check the coupling holes for any burr. Check the coupling bolt
locking pins, for its good condition, if necessary replace the same with new pin. Before placing rotor in
position place LP rear bearing in position. Prepare shaft seal compensator along with gasket (front & rear)
& position them on LP rotor with the help of fixtures or support. Lift rotor with supplied device, leveled it
in zero-zero position & placed slowly in position.
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B) Lift top half of inner – inner casing clean it & place it in position. Apply jointing compound before box up
of casing. Similarly put inner outer casing in position, tighten it & carry out roll check of inner outer-casing.
Adjust the casing by machining packers & radial keys.
C) Centering of front & rear gland boxes of LP Casing, adjust the clearances with keys if necessary.
D) Inspect all extraction bellows & clean the condenser, remove checker plates & ladder put inside
condenser for inspection of bellow, lift outer cover & place it in position with O ring, apply jointing
compound before box up & tighten the casing.
3.14 - ALIGNMENT OF HP, IP AND LP ROTORS
1) Clean all coupling faces before alignment, align all rotors radially, axially & shift them in spigot provided on
couplings.
2) During alignment achieve left & right movement of rotors with the help of radial keys of pedestal, if the
correction is very less than it can be carried out through torous provided on the bottom of the bearing. The
up & down movement, of rotor is to be achieved with the help of adding or subtracting shims in the
cylindrical or spherical seat of bearing.
3) Avoid any adjustment of shims more than 0.3 mm in torous or spherical piece of bearing during the alignment.
 Insure that during alignment the catenary of the rotor is maintained.
4) Put four no of loose bolts in HP/IP, IP/LP coupling, hand tight the loose bolts by keeping gap of about 0.20 to
0.25 mm in coupling face.
5) Rotate the rotor & record the coupling gap at 900 intervals on left right & top position. Ensure that loose bolts,
are remain free while recording the gap of coupling for alignment purpose. Note down the readings, measure
deviation & correct it, try to achieve left right, top-bottom deviation within 0.03 to 0.05 mm.
6) Ensure all coupling bolts are fitted within 0.02 to 0.03 mm clearance & bolts are to be ground within accuracy
of 0.05 mm.
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DETAILED EXPLANATION :
The couplings of turbine shaft are generally rigid couplings; the basic function of any coupling is to
connect two or more shafts together to form a single shaft assembly. The radial and axial alignment of shafts are
to be completed before their coupling and alignment are to be done in such way that the entire shaft assembly
follow the continuous deflection curve given log sheet. The alignment checks determines both the radial and axial
position of two adjacent coupling flanges relative to one another The radial measurement is perform on
circumference of the coupling and axial measurement is performed on gap created in between the two coupling
flanges.
In any turbine generator erection or in overhauling the rotating shafts of the machine are aligned first &
the stationary parts like casings, seals, glands etc. are aligned later. It is necessary to align turbine generator rotors
because of following reasons.
The coupling connecting the shaft assemblies should be free of stresses & moments.
The objective is to avoid cyclic bending stress in the coupling planes, when coupled shafts are rotating in
the bearings, otherwise it would cause crank like moments
Obviously the undesired effect first mentioned, namely that of cyclic bending stresses, can lead to
malfunctions particularly in case where shrunk fit coupling flanges have been used. If the cyclic bending stress
constantly exceeds permissible levels, the coupling flange may get loosen and result in to failure. The second
undesired effects mentioned, namely crank like movement of shaft, and would result in additional dynamic load on
the adjacent journal bearings. The excessive misalignment will result into extra dynamic forces on the bearings
than permissible limits and will result into heavy vibrations of bearings as well as shafts.
3.15 -ROLE-PLAYED BY SHAFT DEFLECTION CURVE IN ALIGNMENT

OPERATION
A shaft which is supported at each end will have a certain degree of sag owning to its dead weight .The
extent of sag is essentially determined by the weight, the diameter & the distance between the bearing supporting
the shaft. The center line of shaft supported in such a manner can therefore no longer be regarded as a true
straight line but will assume more or less curve shape relative to the theoretical center line depending upon the
weight of shafts & the distance between two bearings. The actual center line is termed as shaft deflection curve
(catenary of the machine). It is the fact that this deflection curve remains the same even when the turbine is in
running, which in turn means that allowance must be made for shape of the deflection curves during erection &
overhauls of the machine.
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Deflection curve for Turbine – Generator unit
This is the natural result of the weight factor. Obviously when shaft sag stresses are produced & the restoring
forces originating from these stresses limit the shaft sag. In turbine generator units these natural stresses are
accepted as inevitable. Additional stresses as a result of misalignment, must however, be avoided at all costs. To
satisfy this requirement during erection & overhaul of turbine generator units coupling checks must be employed
to assume optimum alignment of shafts relative to each other.
3.16 - COUPLING CHECK
With the aid of coupling check, it is possible to align the journal bearings so that the deflection curve of a
shaft assembly is continuous. One major precondition in performing the coupling checks is that the bearings
supporting the shafts to be spaces in same way as in later operation. Without doubt, the optimum method of
achieving this is to place the shafts in their intended bearings
The standard coupling check covers firstly the radial position and secondly the axial position of two
adjacent coupling flanges relative to each other. Normally the measurement is taken radially on the circumference
of the adjacent coupling flanges, with the axial measurement being taken on outermost diameter of the inner axial
45
surfaces of the coupling. The measurement itself is taken with the aid of dial gauges or micrometer, or else with a
measuring jig firmly mounted on coupling flange & using a feeler gauge or slip gauge.
To eliminate as far as possible the influence of any axial or radial runouts present in the coupling plane, it
is imperative that the two shafts be turned in same direction and by same amount when the measurement is taken.
Since a measurement is normally taken in the two main planes, vertically and horizontally, at the top and the
bottom as well as on the left and right hand sides in each case, this should be also be turned through 90 degree in
each case.
3.17 - ALIGNMENT PROCEDURE
Draw the meticulously cleaned coupling flanges together using three auxiliary fitting bolts, tight until only a slight
measuring gap is left
Set the measuring jigs in the top position on the coupling of the shaft assembly which are to be measured.
Using marker pen, mark this position with a line on both coupling flanges as “top” and proceeding in clockwise
direction mark “right” & “left position. It is not possible to measure to measure the gap at bottom position of the
coupling, so the bottom gap is calculated from the relation (left gap+ right gap = top gap + bottom gap).
Radial measurement is performed once at each measuring point, axial measurement is performed at
three points (left, right, and top) to compensate slight axial displacement, which are revealed when the shafts are
turned. The precise axial measurement is calculated from the arithmetic mean of the measurements taken at that
point
In detail the procedure is as follows
 Perform radial measurement using measuring jig(dial gauge may also be used) with filler gauge at the top of
the coupling
 Perform axial measurement using feeler gauge (if gap is wide use block gauge also) at right, left and top
coupling flanges.
 Start up jacking oil pump and turn shaft assembly through 90 degree in the direction in which it will rotate in
service, shut down pump (auxiliary coupling bolts must be loose).
 Perform radial measurement at the left of the coupling.
 Perform axial measurement at left, right & top between coupling flanges.
 Rotate the coupling in 180°, 270° & 360°, obtain axial & radial measurements as described above. Calculate
bottom gap from above mentioned relation, and also calculate arithmetic mean of measured gap at each
measurement points.
 Radial correction is applied ½ of the deviation obtained during check and axial correction is applied as it is
obtained during check.
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3.18 - RUNOUT CHECK
After coupling, adjacent shaft ends must be subjected to a final check for concentricity. An additional
measurement has to be taken at the journal area adjacent to the coupling to detect any runout.
Using firmly attached dial gauge; any runout present at journal & coupling areas can be measured by
carefully turning the coupled line of shafting.
If these checks revel runout of more than 0.03 mm, the couplings have not connected properly. It should
be pointed out here that a radial runout at shaft journal of only 0.03 mm is enough to produce an inherent
imbalance of 30 m in later operation.
The cause of the irregularities mentioned above can be due to unevenly tightened couplings, misaligned
centering and lack of parallelism between the couplings. It is imperative in all cases to locate the cause of the
improper connection and eliminate them by appropriate measure.
3.19 - COUPLING
1) Insert all coupling bolts in coupling bolts in coupling holes as per hole number punch on bolt.
2) Ensure freeness of bolts within 0.02 to 0.03 mm, tight four opposite bolts with prescribed elongation &
then check run out at coupling and journal, if the run out is within the limits tight another four bolts with
prescribed elongation. (0.33 to 0. 34 MM) & check run out at coupling & journal.
3) If it is found that run out at particular bolt or coupling & journal is going out of limit, use indifferent
method of tightening to control excess run out at journal & coupling.
4) Coupling bolts are not to be hammered in coupling holes & these are to be fitted with thumb pressure
only.
5) Balancing of coupling bolts by weight.
6) The question of balancing of coupling bolts arises only when the reaming & honing operations are carried
out in overhauling. The coupling bolts are to be balance within 5 gm accuracy.
7) Final balancing of coupling bolts is to be done along with individual bolt. If all coupling holes are of same
size before & after honing & reaming then all the bolts are kept of equal weight. If necessary adjust the
weight of bolts by machining the metal from bolt head or add weight by welding electrode.
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3.20 - REVISIONING OF COMBINED JOURNAL & THRUST BEARING
1. Before removal of bearing measure float of rotor. Measurement of float is necessary before dismantling
of thrust pad, as it is pad thickness deciding factor.
2. Remove the top half, load the rotor on lifting tackle, remove JOP connection & take out bottom half of
bearing. Remove spherical seats & take it out. Assemble the bearing out side & check spherical seat &
spherical support contact. The contact should be full throughout length & area of the spherical seat, no
contact around 25 to 30 mm area from both ends of spherical seat may be accepted.
3. Check the feeler tightness of spherical seat & support, the seat should be feeler tight, check it by inserting
0.03 mm feeler gauge in between gap of spherical seat & support. Check bearing shell parting plane feeler
tightness & pinch of bearing liner. Also check feeler tightness of bearing shell & liner. After tightening
bearing P/P bolts there should not be any gap in between bearing shell & liner.
4. Ensure proper color contract between spherical seat of bearing & pedestal, if required color matching
may be carried out for full contract.
5. Preparation of thrust pads: The thrust pads are dismantle from bearing by taking out holding pins of pads.
The working area of pad is blue matched & the spring elements are removed. Adding or subtracting shims
in between spring element & thrust pad can change the thickness of pad. The float is the thickness
deciding factor for thrust pads, accordingly add shims in between pad & spring element, increase the
thickness & reduce the float of rotor with required value. Take the bearing bottom shell contract with
rotor by placing it on rotor, the contract should be 20 to 30 mm wide & throughout length of liner, this
should be carried out for all bearings & if required corrections are made by hand work.
Check the side contract faces of bearing shell on which the axial keys rests, similarly check
pedestal side contact faces where axial keys rests if any pitting is observed, remove it by hand work
(scrapping). The mating faces of key & block should be surface ground & must have good contact with
pedestal & bearing shell.
The axial keys are prepared after checking parallelism of bearing with pedestal, its axial
positioning & Measurement of side oil clearances. Ensure that the bearing is fully rest on spherical seat
axially.
It should not be assembled in shifted condition from spherical seat. Check the self-aligning
property of bearing by disturbing bearing axially with 0.03 mm & rotating rotor for three to four times &
rechecking its axial position. The bearing should come to its original position (parallel to pedestal) with
the disturbed shift value i.e. 0.03 mm.
Make the bearing parallel with pedestal & measure the axial key gap at all four sides & prepare
the thickness of keys according to measurement. The thickness of keys should be made in such a way that
the keys should go hand tight.\, inside the gap 0.03 mm feeler tight key can be accepted.
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3.21 - BLUE MATCHING OF THRUST BEARING

After completion of reaming / honking & final tightening of coupling the color matching of thrust
bearing pads have to be carried out with respect to thrust collar of HP rotor. During color matching a good
contact, on all pads of front & rear side are to be ensured with respect, to rotor collar by moving rotor in +
ve & -ve direction on its hand rotation. The thrust bearing should be axially lock with axial key during its
color matching of pads. Color is to be applied on the thrust collar of rotor. After color matching of thrust
pads, the axial zero position of rotor is achieved & this can be taken as reference for all other instruments
like axial shift probe, differential expansion probe etc.
3.22 - BEARING REVISIONING
1) Before removal of pedestal top, ensure that all insulation removal work completed.
2) Remove cover & record seal bore readings at all pedestal (front and rear) with the help of inside
micrometer. Put dummy gasket on oil inlet hole of bearing pedestal, at its parting plane.
3) Measure the yoke key clearances take out the keys & remove the yoke.
4) Measure bearing oil – guard clearances & remove it. Remove top half of bearing & measure side oil
clearances with feeler gauge, compare it with available drawing readings, if variation is noticed correct it
from side keys. The correction should be carried out only when it is necessary. Measure the top oil
clearance with the help of lead wire. Place the wire on journal along its axis put top half in position tight it
fully, again remove top half & take out the lead wire & measure the thickness without side micrometer.
The thickness will give the top oil clearance.
5) Put rotor lifting device in position take the load of rotor on device, take out JOP connection & remove the
bottom half of bearing. Take out bearing seat & check the bearing seat contact. Assemble the bearing
check feeler tightness of liner with shell. The liner & shell should be 0.03 mm feeler tight. Inspect bottom
& top half for any damage on babbit. Carry out DPT & ultrasonic of bearing liner to identify any cracks or
babbit looseness.
6) Put the seat in position tight it put little oil for lubrication & place in position. Do not take out two
bearings of same shaft at the same time.
7) For Bearing No. 3, 4 & 5, ensure color contact between cylindrical seat of bearings & pedestal, if required
it by hand work (scrapping). Ensure contact between torous piece of bearing & cylindrical seat of pedestal,
the contract should be line contact through out the seat of width not more than 20 mm. If the contact is
disturb the machine may cause problem while in operation like jamming of bearing gear, heavy pedestal
vibration etc. In case of any variation, it is required to send the same to works for machining the seat
faces. As per recommendations & instructions of M/s BHEL, it is not allowed to achieve contact with hand
machining.
49
Cylindrical support to torous contact for bearing no. 3,4,5
Cylindrical support to torous contact for bearing no. 1&2
3.23 - OIL FLUSHING AND PEDESTAL BOX UP
1) Before oil finishing clean the pedestal completely & remove bearing inlet throttle (for Bearing No. 1, 2, 3,
4, 5 ) & put bearing oil flushing dummies in all throttle, for bearing No. 6 & 7 shock circuit the inlet / outlet
pipe with special pipe connection.
2) Before oil flushing ensure that the insulation work is completed & pedestal oil guard rings are fitted in
position with required clearances. If during operation any pedestal oil leakage noticed, change the brass
fins & machine it with desired clearances. Set it on pedestal with respect to rotor.
3) Ensure that pedestal parting plane is feeler tight after tightening all parting plane bolts. If required color
matching may be carried out by scrapping. The cutting is to be carried out on upper half of the pedestal
cover, Box up all bearings remove gasket dummy from oil inlet at P/P of pedestal & assemble the yoke.
50
Prepare top / bottom yoke keys, by keeping 0.05 to 0.06 mm clearance. Apply jointing compound in
between P/P & box up the pedestal top cover after.
4) Start the oil pump & check the complete oil system for oil leakages. Slowly raise the temperature of oil to
normal working level is 42 0C, run the oil pump for 24 hours, clean the MOT bucket strainer & restart the
pump. Again stop the pump after 24 hours clean the bucket strainer. Remove top covers of all pedestals,
take out dummies from inlet & refit bearing inlet throttle in position. Complete instrumentation and
calibration. Take bearing No. 6 & 7 pedestal in oil circuit by removing shock circuit pipe connection.
Start AOP, now the bearings are taken in oil flushing again the system is checked for leakage, dirt
in MOT strainer is observed is the percentage of dirt is decreasing then put thrust bearing filters in service
& observer the choking rate before putting machine on barring. The thrust bearing filter should stand for
at least 16 hours, conclude the oil flushing & give clearance to barring.
Before box up of pedestal measure final seal bore readings & all other control readings. The
pedestal packers are to be removed, cleaned & contact of each should be checked. The axial keys are
removed, cleaned, lubricated & put back in position. Put machine on barring, observe for oil leakage &
rubbing sound.
3.24 - BUMP CHECK

The bump check is carried out for measurement of axial clearances, between rotor & casing seals, both in
+ve & -ve direction.
Before carrying out bump check measure the float of rotor with pads, adjust the rotor in center position &
counter check with reference readings.
Remove thrust pads, start JOP & move rotor towards HP casing in couples condition with respect to
bearing no 2, either by stopper or with leaver. Keep the rotor in rotation, when the rubbing sound is noticed stop
rotating & note down reading either by dial gauge or inside micrometer. The difference in reference reading &
reading obtained after shift will give IP -ve bump of rotor in that direction. Further Decouple the IP/LP coupling,
close the jacking oil of Bearing No. 3 to avoid shifting of IP rotor. Jack HP rotor towards front side, till it stops
further movement in axial direction. Install another dial gauge on IP rotor coupling to check IP rotor movement, in
–ve direction. The readings are noted, the difference in reference reading and reading after shift will give HP +ve
( shift of IP rotor + shift of HP rotor with reference to IP coupling).
Couple HP/IP rotors, bring back to reference position and move rotor towards IP turbine and measure the
reading, the reference reading and reading obtained after shift will give difference in HP -ve bump.
Similarly, to measure HP +ve bump jack the IP rotor toward generator with reference to HP coupling by
closing jacking oil valve of Bearing No. 2, to avoid slipping of rotor towards HP Turbine. Press the rotor with the
help of stopper towards Generator till it stops moving further in same direction. Measure the readings. The
difference in reference reading and actual reading obtained after shift will give the bump of IP rotor in positive
direction.
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3.25 - HORN DROP TEST
Horn drop test is carried out for measuring the loading of casing on each corner of pedestal. The horn
drop readings are important in the HP & IP casings & may cause serious problems in operation of machine like high
vibrations in machine, failure of barring in hot or cold machine, obstruction during expansion of machine etc.
In horn drop test a drop is measured at an individual corner of the casing with the help of dial indicator by
removing support / packer of individual corner & then it is compared with opposite corner to record indifferent,
loading of casing.
Preparation & Procedure:
1) Ensure availability of four no of hydraulic jacks having capacity of 50 tons each.
2) Ensure four no of jackscrews of size M-60.
3) Place four jacks below Four Corners casing.
4) While recording the horn drop readings the casing must be absolutely free & even the radial or axial keys
of front & rear end of casing either to be removed or made free.
5) A dial gauge is also to be installed on each corner of casing to measure drop.
6) By lifting individual corner with jack the load of casing is supported on hydraulic jack or jacking screw,
then removes the individual packer.
Now gradually the jack is released in support of jacking screw to avoid jack failure or sudden release of
jack due to manual operation (may cause damage to seals). This is carried out at all Four Corners of HP & IP casings
& the drop readings are recorded on dial gauge.
If the corner is lifted by (+) 0.1 mm & packer is removed, then it is allowed to come down (-) 0.1 mm, this
is the zero position of the corner. Further drop from this position will be the drop of the particular corner
accordingly carried out for all Four Corners of casing.
3.26 - ROLL CHECK
This check is carried out in KWU machine for measurement of minimum radial clearance in HP, IP & LP
casing. It is measured by actual movement of casing from right to left & top to bottom, while rotating the rotor by
hand.
The variation in the readings may cause vibrations, obstruction to barring gear & reduced efficiency of
machine. The roll check should be carried out along with checking of centering of casing with respect to rotor. As
per roll check readings, casing centering should be carried out & same readings should be recorded for reference.
The roll check should be carried out in cold machine only.
PROCEDURE :
1) Alignment & coupling of HP, IP & LP rotors to be completed before starting the rolling test of the casing.
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2) Centering readings should be recorded before carrying out the check, as to place casing in its original
position after the check if no corrections are required.
3) Install all jacking screws of HP & IP casing at all four corners along with dial gauges for monitoring up
down & left right movement of casing.
4) Place four hydraulic jacks of 50 T capacities below four corners of casing.
5) Before starting roll check, it should be ensure that rotor is totally free on hand barring, otherwise make it
free by adjusting the lift of rotor at each journal (normally 0.1 to 0.11 mm).
6) Measure the lift of rotor at corresponding journal by starting JOP; usually it is adjusted to 0.1 mm by
throttling jacking oil inlet valve. (Corresponding journal means, for HP casing J-1 & J-2 for IP J-2 & J-3 for
LP J-3 & J-4).
7) Lift the casing at all four corners in step of 0.05 mm to 0.1 mm with the help of hydraulic jack in support of
jacking screws. The rotor is also kept rotating manually side by side with the lifting of casing.
The rotation of rotor & lifting of casing continued till it becomes slightly tight at the seals of casing. After
this lowers the casing by 0.05 mm at all Four Corners & the rotor is rotated again. If the rotor is not completely
free, then 0.05 mm again lowers the casing till the rotor is completely free. After ensuring freeness of rotor it is
again rotated & the casing is lifted on its front end till the rotor rotation becomes tight on seal portion of front end.
As soon as the shaft become tight the lifting of casing & rotation of rotor is stopped, dial readings on front end left
right recorded. The lift on front end of casing gives bottom clearance of front end of casing.
After this the casing is lowered in step of 0.05 mm on front end to achieve freeness of rotor. The rear end
of casing is then lifted in steps of 0.05 mm by keeping rotor in motion. The lifting is continued till rotor become
tight on its seal. The corresponding dial reading on left & right corner of rear end of casing will give bottom
clearance on rear end of casing.
After recording the bottom clearances of front & rear end of individual casings, the casing is lowered back
to its original zero-zero position with hydraulic jack in support of jack screws.
Similar procedure is to be repeated for deciding top clearances of the casing. This may be decided by
lowering casing by removing packers below the corners of the casing, with the help of hydraulic jack in support of
jacking screws. The casing is lowered in step of 0.05 mm to 0.1 mm keeping rotor in motion till it become tight, on
its seals. Front & rear clearance is obtained as started in above procedure & casing is moved back to its original
position.
After recording the top & bottom clearances, the radial keys of casing are removed and again rolling test
for left & right directions are done similar to top / bottom. The procedure is same as that of top / bottom, only the
difference is dial gauges are installed on left & right corners for measurement of left / right clearances. After this
check the casing is brought back to its original position.
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After completion of the rolling test, casing clearances are adjusted as required in radial direction with the
help of radial keys & packers below the horns of casing. Final corresponding centering reading is recorded with
respect to roll check correction.
3.27 - SWING CHECK
Swing check is the measurement of radial throw, caused due to coupling face run out of two coupled
rotors. This is measured on opposite end of coupling at journal where the weight of shaft is less as compared to
other end.
The higher swing check values may cause higher shaft vibration, higher Babbit metal temperature etc. The
value of swing check depends upon axial run out of coupling faces, the diameter of coupling & length of rotor. It is
recommended to keep minimum swing check value for better performance during operation of machine. In
tandem compounding turbine it is essential to measure swing check value on extreme end & where the weight of
rotors is light. In 210/250/500 MW KWU machine it is measure on HP rotor front.
Any variation in the swing check value may be corrected by inter changing the coupling face position or by
correcting the coupling faces with scrapping.
Face run out of all couplings is to be checked for concavity / convexity. This can be checked with the help
light wt straight edge. No. convexity is permitted; concavity of about 0.04 to 0.05 is permitted.
While recording the swing check readings of HP rotor front end is to be supported on lifting device & front
bearing bottom is removed. During swing check the lifting device are to fit properly, the tie rods of lifting device
should be seen for correct, fitting of its spherical bearings etc. The spherical bearings should not obstruct the
movement of shaft radially during checking of swing check.
IT can be carried out in other way by shifting load of rotor on dummy bearing and hanging it to EOT crane
with long sling. Ensure that the rotor is not disturbed radially due to fitting of dummy bearing.
During checking of swing check readings measure radial movement of rotor on parting plane & rotate the
rotor either on jacking oil with hand barring. Avoid jerk during rotation of rotor while recording the swing check
readings.
The final swing check value of HP rotor is to be measured after fitting & elongation of all coupling bolts of
HP-IP & IP-LP rotors. During tightening of coupling bolts the indifferent tightening of bolts may be avoided for
improvement of swing check & sequential tightening may be followed.
During checking of swing check readings the initial few rotations are given to the rotor to avoid initial sag
due to stationary position and then only the readings are to be recorded.
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CHAPTER IV - TURBINE
COMMISSIONING
55
TURBINE COMMISSIONING
TURBINE COMMISSIONING:
It is set of activities required to carry out for rolling of turbine at rated speed safely.
These activities are performed in specific sequence, which is called as commissioning procedure.
The activities are carried out for individual systems and then combined for achieving goal i.e. turbine
commissioning.
Turbine commissioning includes
• Oil flushing of TG system.
• Commissioning of Governing system.
• Commissioning of HP/LP by pass system.
• Flushing of seal oil system.
• Generator air leak test
• Barring operation after all protection trials.
• Rolling and synchronization of machine.
4.1 - OIL FLUSHING

• Oil flushing is done to remove dirt, welding slag etc.after completion of erection or overhaul. By creating
conditions similar to the machine in operation
• If the dirt, welding slag is carried over with oil there is every chance of damage to bearings.
PROCEDURE
• MOT oil filling completed through centrifuge
• Level should be 80% above normal operating level
• Trial run of vapor extraction fans should be completed and bearings are kept by passed by putting
dummies in oil inlet.
• First charging of oil system is done by starting EOP to avoid leakages and proper venting as disch. Pr.is less
than AOP.
• Once the system is completely filled AOP to be run for further flushing.
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• Thermal shocks given during the process
• Oil temperature is raised to 75 Deg.C.
• Heating is to be stopped & oil is cooled by opening the CW valves to coolers till the temp. of oil goes down
to min. possible value.
• As soon as temp. drops ,start heating up.
• Continue this thermal shock method along with manual tapping of oil lines on its complete length.
• Filters in MOT are to cleaned regularly during flushing operation.
• After initial flushing like this, bearings are included in flushing operation.
• Monitor return flow of oil in pedestal drain at each bearing.
CRITERIA FOR COMPLETION OF FLUSHING
• Oil sample at inlet of COP should be free from moisture and mechanical impurities.
• Duplex oil filter/MOT filter should be free from impurities; no chocking of filters should be experienced in
duration of 24 hours.
• On the basis of above results oil flushing can be concluded.
4.2 - COMMISSIONING OF GOVERNING SYSTEM

• Ensure that AOP is running and tank oil temperature 500 C.
• Open all oil drains of system including servomotors.
• Charge the governing rack by opening manual isolating valves provided on rack.
• Ensure that turbine trip solenoid supply is made off.EHC is to be kept isolated.
• Ensure control oil pressure is available on rack.
• Close trip oil valves to ESV servomotor & Secondary oil valves in HPCV, IPCVs.
• Close starting device and ensure resetting of all turbine protections.
• Open starting device and ensure oil pressure in trip oil, secondary oil ckt.
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• Close the starting device and open all valves previously closed.
• Open starting device gradually, ensuring speeder gear to its max. position.
• At 30-40% of starting device stop valves will open.
• From 50% onwards control valves start open. Ensure that at 2.5Kg/cm2 of HPSO HPCV starts opening. at
2.5Kg/cm2 of IPSO IPCV starts opening. HPCV will open first followed by IPCV.
• Record the characteristics of valves .i.e valve lift verses secondary oil pressure.
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Operate Main Trip valve and ensure closure of valve.
 Normalized the system.
4.3 - COMMISSIONING OF HP BYPASS SYSTEM

• Ensure that HP Bypass oil station is filled with oil.
• The pump supply is to be made normal.
• Ensure that oil pipe lines connected to valve servo motor are tightened properly in order to prevent high
oil pressure leakage.
• Start the oil pump and vent the system if necessary.
• Opened oil isolating valve going to each servo motor.
• Ensure Nitrogen pressure in the system.
• Operate the individual servo motor block valve from local & ensure full opening of each valve, main as
well as spray valve.
• If necessary adjust the stroke of valve by changing.
4.4 - COMMISSIONING OF LP BYPASS SYSTEM

• Open control oil inlet valve to rack & ensure control oil pressure available on rack.
• Bypass low vacuum, Low injection water pressure protection and Bypass limiter.
• Operate controller & check signal oil pressure to its fullest value.
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• Bring back to controller at zero position and start recording characteristic of valve verses signal oil
pressure.
• Ensure following sequence.
a) Spray valve open first. at 1.5 Kg/Cm2 of signal oil
b) Stop valve open to full opening at 2 Kg/Cm2 of signal oil followed by.
c) Control valve start opening. at 2 to 4.8 Kg/Cm2 of signal oil
4.5 - COMMISSIONING OF SEAL OIL SYSTEM

Prior to the commissioning system is to be flushed by fitting loops at DPR, Ring relief and seal oil inlet to TE
and EE lines followed by procedure.
• Ensure proper oil level in SOST as well as SOT.
• Ensure supply of all pumps in normal condition.
• Ensure that pump suction - discharge valves are in open condition.
• Ensure that DPR Isolating valves are kept open.
• Ensure that IOT & SOT float isolating valves are in open condition.
• Ensure IOT to SOT Bypass Valve is closed.
• Start SOP from local & check for oil leakage. Ensure Seal oil pressure and differential pressure.
• Checked hydrogen side & air side return flow from seal assembly. Kept liquid in generator valve opened.
• Start vacuum pump for venting purpose. If the system is normal shift control to remote.
• Complete the different trial from control room & give clearance for air filling in the generator stator.
• Gradually increased the air pressure & observed the DP. Keep eye on liquid in generator protection.
• Increase the pressure to rated pressure in step of 0.5 Kg/cm2. Observed the air pressure in casing.
• Record the drop in air pressure after interval of one hour.
• If the drop in pressure is 0.3 Kg/cm2. in 24 hours. Then conclude the test & give clearance for hydrogen
filling.
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4.6 - ROLLING OF TURBINEGENERAL CONDITION

1. Ensure that all turbine trips checks has been completed and turbine is reset i.e. the starting device is at
0% and trip fluid and start up fluid pressure are > 6.5 Kg/cm2 and aux sec fluid, HP & IP Sec fluid pressure
are <2.5 Kg/cm2.
2. Ensure that the lub oil temp. control valve is in auto and set point is 42-45 deg C.
3. Ensure that all MAL drains (both motorized and their isolating valves) are open.
4. Ensure that the MS lines drains (MS 105, 106 & 109) to atmospheric flash tank are open.
5. Ensure that the HPBP warm up line isolating valves and motorized valves (BD 3 & 4) are closed and the
warm up line drain (BD 6 & 8) TO ATMFT are open.
6. Ensure turbine is on barring gear with all interlock and protections (SLC of AOP I & II, EOP, JOP I, JOP II,
SOP I & II and DC SOP are on.)
7. Ensure that one oil vapour, one control fluid vapour & one bearing chamber exhauster are running.
8. Ensure that at least 1 CEP, 1 CWP & 1 CW booster pump is running. Ensure CEP is in operation with GSC in
service.
9. Ensure that H2 pressure in generator >2.8 Kg/cm2 and its purity is > 97%.
10. Ensure that the gland steam line isolating valve in closed condition and drain valve to atmosphere in open
condition.
11. Boiler is in lighted up condition with BFP in service. MS steam pressure 15-20 Kg/cm2 and temp 200-250
deg. C .
12. Close the vacuum breaker valve and run both vacuum pumps.
13. Charge MS line by MS 1 & 2 bypass valves (MS 3, 4, 5 & 6).
14. After initial warm up of MS line and PRDS line open the MS line main valves (MS 1 & 2) and establish PRDS
pressure and temperature.
15. Run one gland steam exhauster.
16. Ensure that the gland steam temp. before supply valve is >190 deg.C. and condenser vacuum is more -0.2
Kg/cm2.
17. Close vacuum breaker valve and admit gland steam. Maintain G.S. pressure of 250 mm of water column
with gland steam control valve.
18. After achieving vacuum more than 0.8 Kg/cm2 open the HRH /CRH strainer drains (HRH 101 & 102) and
LPBP warm up line drains (HRH 103 & 104) AND CRH line drains (CRH -101) TO HPFT.
19. Open HPBP warm up valves (BD 3&4) and ensure that there is no water hammering. After warm up (CRH
& HRH line temp. >100 deg C& pressure >1.5 Kg/cm2), slowly open LPBP by 2-5 %. Ensure that the
injection water valve is open by at least 50%.
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20. Reset the LPBP tripping. Once the HRH pressure is > 2 Kg/cm2, open LPBP spray valve first and then LPBP
stop and control valves. While opening the LPBP spray valves ensure that the CEP discharge header
pressure should not reduce < 20 Kg/cm2.
21. Open HPBP, raise the boiler parameter to 40-50 Kg/cm2 , and temp 350-375 deg C and HRH parameter -4-
12 Kg/cm2 @300 Deg C. by opening the LPBP control valves.
22. Ensure that condenser vacuum is <-0.85 Kg/cm2.
23. Ensure there is no hold up from Generator / bo8iler end for turbine rolling.
24. Ensure that all ESV, IPSV and HP & IP control valves are closed and control fluid lines to governing rack
and control valves are lined up.
4.7 - HYDRAULIC ROLLING

1. Ensure that the governing rack isolating valves in the secondary fluid lines of HP & IP control valves are
isolated from EHG.
2. Ensure the starting device and speeder gear are at 0%
3. Ensure turbine is on barring gear with all interlock and protections.
4. Open the starting device up to 25-27% slowly, the ESVs will start opening, wait for ESVs to open full. Raise
the start up device further such that IPSVs start opening, wait for IPSVs to open full. Leave the start up
device at that position.
5. After opening ESVs & IPSV s wait for stop valves & HP & IP turbine casing and shaft temperature to
stabilize.
6. Ensure that no vibrations (bearing pedestals or shaft) and bearing temps are above the alarm limits.
7. Ensure that the lub oil temperature after cooler is 42-45 0C.
8. Ensure that X 4 & X5 Criteria for rolling are satisfied and proper margins of TSE (>30 deg K) are available.
9. Now open the start up device very slowly keeping watch on the turbine speed. Turbine speed will increase;
hold the speed at 600 rpm. by positioning the start up device.
10. Ensure that with rise in speed the primary oil pressure should increase (check out from local gauge
reading). If the primary oil pressure does not increase (around 0.5-0.8 Kg/cm2 at 600 rpm), reduce start
up device to close the control valves and speed is reduced. Investigate the reason.
11. If primary pressure increases with speed then, the speed is to be maintained at around 600 rpm. During
speed up first gate valve gearing will close at 240 rpm and at 540 rpm JOP will be OFF on auto.
12. Allow the turbine to soak at 600 rpm and monitor the casing expansions, bearing and shaft vibrations,
bearing metal temperatures and axial shift reading.
13. Compare the turbine speed in control room with tachometer (for first rolling) for its correctness.
14. Ensure that TSE margin and CRITERIA X-6 before rolling is to be satisfied.
15. Take clearance from generator and boiler end for rolling.
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16. Ensure that generator H2 cooler and exciter cooler are charged from cooling waterside.
17. Ensure that no parameters are above the alarm limits.
a) Bearing vibration < 84 Microns.
b) Shaft vibration < 200 Microns.
c) Axial shift < +-0.5 MM.
d) LP Hood Temp. < 90 0C.
e) Diff. Expansion +2 mm
f) Diff. Temp HPT +-55 0C
g) Diff. Temp. IPT +-45 0C
18. Open start up device very slowly. Turbine speed will rise. At around 2500-2800 rpm the speed will try to
stabilize, this is called governor take over speed. With starting device full open the speed will not
increased beyond this value. Ensure the primary oil pressure in the local gauge is around 1.8-2.0 Kg/cm2,
to increase speed further, we need to increased the speeder gear. From 0%
19. Now open the starting device full. Speed will not increase beyond take over speed of governor.
20. Slowly raise the speeder gear from 0%.
Adjust the speeder gear position such that the speed is maintained at 3000 rpm. At about 2950 rpm MOP
will take over and running AOP will be cut off on auto.
21. Ensure that the lub oil temp after cooler is not increasing beyond set value (45 0C). Allow soaking of
turbine at rated speed and wait for thermal stabilization of turbine casings. Observe for any abnormality
for any of the above parameters and bearing metal temps and vibrations.
22. Ensure that sufficient TSE margin (>30 deg K) and X7 criteria are available.
23. Give clearance for synchronization of unit.
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4.8 - TURBINE START UP CURVES

Turbine Start-up Curves (Criterion) X1 & X3
64
Turbine Start-up Curves (Criterion) X2
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CHAPTER V - HP TURBINE
PHOTOGRAPHS
70
HP TURBINE PHOTOGRAPHS
5.1 - LIFTING HP MODULE
5.2 - PLACING ON STAND AT UNLOADING BAY
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5.3 - FRONT END OF CASING
5.4 - REAR END OF CASING
72
5.5 - ARRANGEMENT OF HPT COMPLETE ROLL CHECK
5.6 - ROLL CHECK OF HP CASING
73
5.7 - FITTING OF ROLL CHECK DEVICE
5.8 - REMOVAL OF HP REAR SEALS
74
5.9 - CASING VERTICAL FIXTURE
5.10 - ASSEMBLY OF RADIAL LOCK BEFORE MAKING CASING VERTICAL
75
5.11 - ASSEMBLY OF RADIAL LOCK AT FRONT END COMPLETE
5.12 - MAKING MODULE VERTICAL
76
5.13 - JACKING ARRENGEMENT OF INNER CASING
5.14 - ARRANGEMENT OF HYDRAULIC JACKS
77
5.15 - FITTING PIN BEFORE TILTING HPT INNER CASING ON STAND
5.16 - INNER CASING LOCKING/THREADED RING REMOVED
78
5.17 - LOCKING SEGMENTS
5.18 - VALVES
79
5.19 - INNER CASING ADDITIONAL JACKING ARRANGEMENT
80
5.20 - INNER CASING AND ROTOR RADIAL LOCK ARRANGEMENT
5.21 - LIFTING INNER CASING FROM OUTER CASING
81
5.22 - PLACING INNER CASING ON HORIZONTAL FIXTURE
82
83
84
5.23 - HP TURBINE INNER CASING
85
5.24 - INTERNALS
5.25 - HPT FRONT GLAND BUSH
86
5.26 - HPT ROTOR
5.27 - HPT INNER CASING
87
HPT INNER CASING
88
HP MODULE DOCUMENTS
CHAPTER VI - HP MODULE
DOCUMENTS
89
HP MODULE DOCUMENTS
6.1 - HP TURBINE – INNER CASING (PARTING PLANE GAP)
H P TURBINE -INNER CASING

(PARTING PLANE GAP)
POSITION MEASUREMENT “A” (inside or outside the casing)

1 2 3 4 5 6 7 8 9 10 11 12 13 14
LOOSELY
SEATED
TIGHTENED
COLD
TIGHTENED
WARM
MEASUREMENT “B” (with 0.04 mm feeler)
LOOSELY
SEATED
TIGHTENED
COLD
TIGHTENED
WARM
90
HP MODULE DOCUMENTS
6.2 - HP TURBINE – INNER CASING (OVALITY MEASUREMENT)
NORMAL POSITION
DIMENSION CONDITION
DIA 1 2 3 4 5
Loosely Seated
Tightened Cold
a
Tightened
Warm
Loosely Seated
Tightened Cold
b
Tightened
Warm
Loosely Seated
Tightened Cold
c
Tightened
Warm
NOTE : 1. Joint gap and ovality measurement should preferably be done together
2. Parting plane studs may be tightened up to +60% to minimize joint gap.
3. If joint gap is 1.5 mm or less with top half being loosely seated and nominal
4. If joint gap is 1.5 mm or less with top half being loosely seated and also b is less than c, no further joint
gap measurement need be done.dia does not fall below 1 mm max., no further ovality measurement need be done.
91
HP MODULE DOCUMENTS
6.3 - RADIAL CLEARANCES AT GUIDE BLADES OF HP TURBINE
UPPER HALF/LOWER HALF

(DURING DISMANTLING / AFTER FINAL ASSEMBLY)
Radial Clearances as per Drg. 0.60
SEAL SEAL SEAL

STAGE LEFT RIGHT STAGE LEFT RIGHT STAGE LEFT RIGHT
NO. NO. NO.
25 1 16 1 7 1
2 2 2
3 3 3
24 1 15 1 6 1
2 2 2
3 3 3
23 1 14 1 5 1
2 2 2
3 3 3
22 1 13 1 4 1
2 2 2
3 3 3
21 1 12 1 3 1
2 2 2
3 3 3
20 1 11 1 2 1
2 2 2
3 3 3
19 1 10 1 1 1
2 2 2
3 3 3
18 1 9 1 1
2 2 2
3 3 3
17 1 8 1 1
2 2 2
3 3 3
1) NOTE : The seals shall be numbered beginning from Turbine side for each stage.
92
HP MODULE DOCUMENTS
6.4 - RADIAL CLEARANCES AT MOVING BLADES OF HP TURBINE

UPPER HALF/LOWER HALF
Radial Clearances as per Drg. 0.60
NOTE : The seals shall be numbered beginning from Turbine side for each stage.
SEAL SEAL SEAL
STAGE LEFT RIGHT STAGE LEFT RIGHT STAGE LEFT RIGHT
NO. NO. NO.
25 1 16 1 7 1
2 2 2
3 3 3
24 1 15 1 6 1
2 2 2
3 3 3
23 1 14 1 5 1
2 2 2
3 3 3
22 1 13 1 4 1
2 2 2
3 3 3
21 1 12 1 3 1
2 2 2
3 3 3
20 1 11 1 2 1
2 2 2
3 3 3
19 1 10 1 1 1
2 2 2
3 3 3
18 1 9 1 1
2 2 2
3 3 3
17 1 8 1 1
2 2 2
3 3 3
93
HP MODULE DOCUMENTS
6.5 - AXIAL CLEARANCES BETWEEN BLADES OF HP TURBINE
UPPER HALF
CASING CASING
+5.5 b b
+
3 a 2 a 1 a +5.5
+
ROTOR ROTOR
AXIAL CLEARANCES OF MOVING BLADES

(+) DIRECTION (b) (-) DIRECTION (a)
STAGE
AS OBSERVED AS OBSERVED
AS PER DRG AS PER DRG
LEFT LEFT RIGHT
25 - 4.7
24 5.8 4.7
23 5.8 4.7
22 5.8 4.7
21 5.8 4.7
20 5.8 4.7
19 5.8 4.7
18 5.8 4.8
17 5.8 4.8
16 5.8 4.8
15 5.8 4.8
14 5.8 4.8
13 5.8 4.8
12 5.8 4.8
11 5.8 4.8
10 5.8 4.8
9 5.8 4.8
8 5.8 4.8
7 5.8 4.8
6 5.8 4.8
5 5.8 4.8
4 5.8 4.8
3 5.8 4.8
2 5.8 4.8
1 5.8 4.8
94
HP MODULE DOCUMENTS
6.6 - AXIAL CLEARANCES BETWEEN BLADES OF HP TURBINE
LOWER HALF
CASING CASING
+5.5 b b
+
3 a 2 a 1 a
+5.5
+
ROTOR ROTOR
AXIAL CLEARANCES OF MOVING BLADES

(+) DIRECTION (b) (-) DIRECTION (a)
STAGE
LEFT RIGHT LEFT RIGHT
25 - 4.7
24 5.8 4.7
23 5.8 4.7
22 5.8 4.7
21 5.8 4.7
20 5.8 4.7
19 5.8 4.7
18 5.8 4.8
17 5.8 4.8
16 5.8 4.8
15 5.8 4.8
14 5.8 4.8
13 5.8 4.8
12 5.8 4.8
11 5.8 4.8
10 5.8 4.8
9 5.8 4.8
8 5.8 4.8
7 5.8 4.8
6 5.8 4.8
5 5.8 4.8
4 5.8 4.8
3 5.8 4.8
2 5.8 4.8
1 5.8 4.8
95
HP MODULE DOCUMENTS
6.7 - AXIAL SEAL STRIP CLEARANCES OF MOVING BLADES OF HPT

M O V IN G BLA D E
UPPER PART LOWER PART

AS AS AS AS AS AS AS AS
PER OBSERVED PER OBSERVED PER OBSERVED PER OBSERVED
STAGE NO
STAGE NO
DR DR DR DR
SEALING
SEALING
LE RIG LE RIG LE RIG LE RIG
G FT HT G FT HT G FT HT G FT HT
NO
NO
2 1 5.9 - - - 25 1 5.9 - - -
5 2 5.9 - - 4.5 2 5.9 - - 4.5
2 1 5.9 4.5 - - 24 1 5.9 4.5 - -
4 2 5.9 - - 4.5 2 5.9 - - 4.5
2 1 5.9 4.5 - - 23 1 5.9 4.5 - -
3 2 5.9 - - 4.5 2 5.9 - - 4.5
2 1 5.9 4.5 - - 22 1 5.9 4.5 - -
2 2 5.9 - - 4.5 2 5.9 - - 4.5
2 1 5.9 4.5 - - 21 1 5.9 4.5 - -
1 2 5.9 - - 4.5 2 5.9 - - 4.5
2 1 5.9 4.5 - - 20 1 5.9 4.5 - -
0 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 19 1 5.9 4.5 - -
9 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 18 1 5.9 4.5 - -
8 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 17 1 5.9 4.5 - -
7 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 16 1 5.9 4.5 - -
6 2 - - - 4.5 2 - - - 4.5
96
HP MODULE DOCUMENTS
AXIAL SEAL STRIP CLEARANCES OF MOVING BLADES OF HPT

STAGE NO
STAGE NO
SEALING
SEALING
DR LE RIG DR DR LE RIG DR LE RIG
G FT HT G G FT HT G FT HT
NO
NO
1 1 5.9 - - - 15 1 5.9 - - -
5 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 14 1 5.9 4.5 - -
4 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 13 1 5.9 4.5 - -
3 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 12 1 5.9 4.5 - -
2 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 11 1 5.9 4.5 - -
1 2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 10 1 5.9 4.5 - -
0 2 5.9 - - 4.5 2 5.9 - - 4.5
9 1 5.9 4.5 - - 9 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
8 1 5.9 4.5 - - 8 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
7 1 5.9 4.5 - - 7 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
6 1 5.9 4.5 - - 6 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
5 1 5.9 4.5 - - 5 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
4 1 5.9 4.5 - - 4 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
3 1 5.9 4.5 - - 3 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
2 1 5.9 4.5 - - 2 1 5.9 4.5 - -
2 5.9 - - 4.5 2 5.9 - - 4.5
1 1 5.9 4.5 - - 1 1 5.9 4.5 - -
2 - - 4.5 2 - - 4.5
97
HP MODULE DOCUMENTS
6.8 - AXIAL SEAL STRIP CLEARANCES OF GUIDE BLADES OF HP TURBINE

STAGE NO
STAGE NO
SEALING
SEALING
DRG LE RIG DRG DRG LE RIG DRG LE RIG
FT HT FT HT FT HT
NO
NO
25 1 6.4 5.0 6.4 5.0
24 1 6.4 5.0 6.4 5.0
23 1 6.4 5.0 6.4 5.0
22 1 6.4 5.0 6.4 5.0
21 1 6.4 5.0 6.4 5.0
20 1 6.4 5.0 6.4 5.0
19 1 6.4 5.0 6.4 5.0
18 1 6.4 5.0 6.4 5.0
17 1 5.0 4.4 5.0 4.4
16 1 5.0 4.4 5.0 4.4
15 1 5.0 4.4 5.0 4.4
14 1 5.0 4.4 5.0 4.4
13 1 5.0 4.4 5.0 4.4
12 1 5.0 4.4 5.0 4.4
11 1 6.4 5.0 6.4 5.0
10 1 6.4 5.0 6.4 5.0
9 1 6.4 5.0 6.4 5.0
8 1 6.4 5.0 6.4 5.0
7 1 6.4 5.0 6.4 5.0
6 1 6.4 5.0 6.4 5.0
5 1 6.4 5.0 6.4 5.0
4 1 6.4 5.0 6.4 5.0
3 1 6.4 5.0 6.4 5.0
2 1 6.4 5.0 6.4 5.0
1 1
98
HP MODULE DOCUMENTS
6.9 - HP SHAFT SEALING RADIAL AND AXIAL CLEARANCES

(FRONT)
NOTE : The sealing strips shall be numbered successively beginning at turbine side
RADIAL CLEARANCE “d” AXIAL CLEARANCES TOL:  0.5
AS PER AS AS PER + DIRECTION (b) AS PER - DIRECTION
DRG OBSERVED DRG DRG (a)
STRIP NO.
SEALING
LEFT RIGHT LEFT RIGHT LEFT RIGHT

RING
A 1 0.6 - - - -
2 0.6 3.65 3.65
3 0.6 3.65 - - 3.65 - -
4 0.6 3.65 3.65
5 0.6 3.65 - - 3.65 - -
6 0.6 3.65 3.65
7 0.6 3.65 - - 3.65 - -
8 0.6 3.65 3.65
9 0.6 3.65 - - 3.65 - -
10 0.6 3.65 3.65
11 0.6 3.65 - - 3.65 - -
12 0.6 3.65 3.65
13 0.6 3.65 - - 3.65 - -
14 0.6 3.65 3.65
99
HP MODULE DOCUMENTS
HP SHAFT SEALING RADIAL AND AXIAL CLEARANCES (FRONT)


AS PER AS AS PER + DIRECTION (b) AS PER - DIRECTION (a)
STRIP NO.
DRG OBSERVED DRG DRG

SEALING

RING
B 15 0.6
16 0.6 3.65 3.65
17 0.6 3.65 3.65
18 0.6 3.65 3.65
19 0.6 3.65 3.65
20 0.6 3.65 3.65
21 0.6 3.65 3.65
22 0.6 3.65 3.65
23 0.6 3.65 3.65
24 0.6 3.65 3.65
25 0.6 3.65 3.65
26 0.6 3.65 3.65
27 0.6 3.65 3.65
28 0.6 3.65 3.65
C 29 0.6
30 0.6 3.65 3.65
31 0.6 3.65 3.65
32 0.6 3.65 3.65
33 0.6 3.65 3.65
34 0.6 3.65 3.65
35 0.6 3.65 3.65
36 0.6 3.65 3.65
37 0.6 3.65 3.65
38 0.6 3.65 3.65
39 0.6 3.65 3.65
40 0.6 3.65 3.65
41 0.6 3.65 3.65
42 0.6 3.65 3.65
D 43 0.6
44 0.6 3.65 3.65
45 0.6 3.65 3.65
46 0.6 3.65 3.65
47 0.6 3.65 3.65
48 0.6 3.65 3.65
100
HP MODULE DOCUMENTS
HP SHAFT SEALING RADIAL AND AXIAL CLEARANCES (FRONT)


STRIP NO.

SEALING

RING
49 0.6 3.65 3.65

50 0.6 3.65 3.65
51 0.6 3.65 3.65
52 0.6 3.65 3.65
53 0.6 3.65 3.65
54 0.6 3.65 3.65
55 0.6 3.65
56 0.6 3.65
E 57 0.4
58 0.4 3.65 3.65
59 0.4 3.65 3.65
60 0.4 3.65 3.65
61 0.4 3.65 3.65
62 0.4 3.65 3.65
63 0.4 3.65 3.65
64 0.4 3.65 3.65
65 0.4 3.65 3.65
66 0.4 3.65 3.65
67 0.4 3.65 3.65
68 0.4 3.65 3.65
69 0.4 3.65 3.65
70 0.4 3.65 3.65
71 0.4 3.65 3.65
72 0.4 3.65 3.65
73 0.4 3.65 3.65
74 0.4 3.65 3.65
75 0.4 3.65 3.65
76 0.4 3.65 3.65
77 0.4 3.65
78 0.4 3.65
F 79 0.4
80 0.4 3.65 3.65
81 0.4 3.65 3.65
101
HP MODULE DOCUMENTS
HP SHAFT SEALING RADIAL AND AXIAL CLEARANCES

(FRONT)

STRIP NO.

SEALING

RING
82 0.6 3.65 3.65

83 0.6 3.65 3.65
84 0.6 3.65 3.65
85 0.6 3.65 3.65
86 0.6 3.65 3.65
87 0.6 3.65 3.65
88 0.6 3.65 3.65
89 0.6 3.65 3.65
E 90 0.4 3.65 3.65
91 0.4 3.65 3.65
92 0.4 3.65 3.65
93 0.4 3.65 3.65
94 0.4 3.65 3.65
95 0.4 3.65 3.65
96 0.4 3.65 3.65
97 0.4 3.65 3.65
98 0.4 3.65 3.65
99 0.4 3.65
100 0.4
102
HP MODULE DOCUMENTS
6.10 - HP SHAFT SEALING (REAR) TS (ASSEMBLY) RADIAL AND AXIAL

CLEARANCES
DETAIL - II
NOTE : The seals strips shall be numbered successively beginning at Turbine Side.
AS PER AS AS PER + DIRECTION (a) AS PER - DIRECTION (b)
DRG calculated DRG DRG
STRIP NO.
SEALING

RING
M
1 0.40 - - - -
2 0.40 6.4 4.4
3 0.40 6.4 - - 4.4 - -
4 0.40 6.4 4.4
5 0.40 6.4 - - 4.4 - -
6 0.40 6.4 4.4
7 0.40 6.4 - - 4.4 - -
8 0.40 6.4 4.4
9 0.40 6.4 - - 4.4 - -
10 0.40 6.4 4.4
L
11 0.40 - - - -
12 0.40 6.4 4.4
13 0.40 6.4 - - 4.4 - -
14 0.40 6.4 4.4
15 0.40 6.4 - - 4.4 - -
16 0.40 6.4 4.4
17 0.40 6.4 - - 4.4 - -
18 0.40 6.4 4.4
19 0.40 6.4 - - - -
20 0.40 6.4 - - -
103
HP MODULE DOCUMENTS
HP SHAFT SEALING (REAR) TS (ASSEMBLY) RADIAL AND AXIAL CLEARANCES

NOTE : The seals strips shall be numbered successively beginning at Turbine Side.
AS PER AS AS PER + DIRECTION (a) AS PER - DIRECTION (b)

STRIP NO.
DRG calculated DRG DRG

SEALING

RING
K
21 0.40 - - - -
22 0.40 6.4 4.4
23 0.40 6.4 - - 4.4 - -
24 0.40 6.4 4.4
25 0.40 6.4 - - 4.4 - -
26 0.40 6.4 4.4
27 0.40 6.4 - - 4.4 - -
28 0.40 6.4 4.4
29 0.40 6.4 - - 4.4 - -
30 0.40 6.4 4.4
31 0.40 - - 4.4 - -
32 0.40 6.4 4.4
33 0.40 6.4 - - 4.4 - -
34 0.40 6.4 4.4
35 0.40 6.4 - - - - -
36 0.40 6.4 - - -
J
37 0.40 - - - -
38 0.40 6.4 4.4
39 0.40 6.4 - - 4.4 - -
40 0.40 6.4 4.4
41 0.40 6.4 - - 4.4 - -
42 0.40 6.4 4.4
43 0.40 6.4 - - 4.4 - -
44 0.40 6.4 4.4
45 0.40 6.4 - - 4.4 - -
46 0.40 6.4 4.4 - -
104
HP MODULE DOCUMENTS
6.11 - HP SHAFT SEALING ASSEMBLY
TEST LOAD
DETAIL - I
SEALING NO. a b c
AS PER DRAWING
O 0.1-0.2 -
AS OBSERVED
FRONT LEFT RIGHT LEFT RIGHT LEFT RIGHT
A
B
C
D
E
F
G
H
REAR
M
L
105
HP MODULE DOCUMENTS
6.12 - HP SHAFT BEARING REAR (ASSEMBLY)
SEALING RING NO a b c d
AS PER DRAWIG
0.2 – 0.3 0.20 0.5 5.0
AS OBSERVED
K
106
HP MODULE DOCUMENTS
6.13 - MINIMUM RADIAL CLEARANCE IN THE BLADE SECTION OF HP

TURBINE (ASSEMBLY)
GUIDE BLADES
MOVING BLADES
MINIMUM RADIAL CLEARANCE AS PER DRAWING:-
GUIDE BLADES (a) 0.6 mm MOVING BLADES (b) 0.6 mm TOTAL (a+b) 1.20 mm
ALIGNMENT
TS GS
RADIAL CLEARANCES AS OBSERVED
TS GS
TOLERANCE : ALIGNMENT  0.05 mm

RADIAL CLEARANCES > Nominal as per Drawing 0.1 mm
107
HP MODULE DOCUMENTS
6.14 - MINIMUM AXIAL CLEARANCES WITHOUT SHAFT SEAL (BUMP CHECK)
+VE -VE
TOLERANCE = +-0.7 mm
AXIAL DISPLACEMENT IN +VE DIRECTION (a) IN –VE DIRECTION (b) TOTAL

OF ROTOR AS PER AS AS PER AS AS PER AS
DRG. OBSERVED DRG. OBSERVED DRG. OBSERVED
IN INNER CASING UPPER PART 5.0 4.4 9.4
(WITHOUT SHAFT –SEALS)
IN INNER CASING LOWER PART 5.0 4.4 9.4
IN INNER CASING ASSEMBLED 5.0 4.4 9.4
108
HP MODULE DOCUMENTS
6.15 - HP CASING ASSEMBLY JOINT FLANGE BOLTS – TIGHTENING &

ELONGATION
OBSERVED VALUES
Part No of Bolt Nominal Length Gauge Length Elongation of Angle of Remarks

gauge length Rotation of Nut
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
123
124
125
126
127
128
129
109
HP MODULE DOCUMENTS
6.16 - ELONGATION OF BOLTS (HPC EXHAUST ELBOWS)
BOLT NO. MEASURED LENGTH (L) ELONGATION (mm)  L ANGLE OF ROTATION

BEFORE TIGHTNING
AFTER DESIGN ACTUAL CALCULATED ACTUAL
TIGHTNING
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
110
HP MODULE DOCUMENTS
6.17 - HP CASING ASSEMBLY
(Reference Dimensions at the casing)
DETAIL - I (SH.NO.1)
DETAIL - II
MEASURE AS PER DRG AS OBSERVED

TOP RIGHT BOTTOM LEFT
a 11  0.5
b 10  0.5
c 0.005 – 0.035
d 0.015 – 0.065
e 0.005 – 0.035
f 0.015 – 0.065
g 0.0 – 0.20
h 7.0
i 3.0
111
HP MODULE DOCUMENTS
HP CASING ASSEMBLY
DETAIL - X VIEW - M

RIGHT LEFT
TOP BOTTOM TOP BOTTOM
a 0.0 – 0.20
b -
c -
NUMBERING IS CLOCK WISE BEGINNING AT THE TOP
d 0.05 – 0.15 1 2 3
e 0.05 – 0.15 1 2 3
112
HP MODULE DOCUMENTS
HP CASING ASSEMBLY
SECTION - KK
AS AS OBSERVED
MEA-
PER FITTING KYEY NO.
SURE
DRG. 1 2 3 4 5 6 7 8 9 10 11 12
A 0.04-0.05 - - - - - - - -
B 0.08-0.10 - - - - - - - - - - -
C 0.08-0.10 - - - - - - - - - - -
D - - - - -
E - - - - - - - - -
F - - - - -
113
HP MODULE DOCUMENTS
HP CASING ASSEMBLY – ASSEMBLY & ALIGNMENT DIMENSIONS
PRE ASSY ASSEMBLY DIMENSIONS

AS PER DRAWING AS OBSERVED
ASSEMBLY CONDITION
OPERATING CONDITION
ASSEMBLY CONDITION
OPERATING CONDITION
h - * 100 -
FINAL ASSY a - * 475 -
g - 935 -
c - * 190 -
h 100.3 * 100 -
MEASURE SETTING DIMENSIONS

AS PER DRAWING AS OBSERVED
During Measurement Operating
of During Measurement of Axial Operating
Axial Clearances Condition Clearances U/H Conditions L/H
A * 475 * 475
B * 490 * 490
C - * 190
D - 375
E - 25
F - 285
TO BE TAKEN FROM DRAWING
114
HP MODULE DOCUMENTS
6.18 - ASSEMBLY DIMENSIONS AT THE CASING
U1 e
THICKNESS OF FITTING PIECES
NOTE : THE ABOVE MEASUREMENT IS REQUIRED IN CASE ‘U’ RING IS REPLACED
MEASURE AS PER DRG. AS OBSERVED

a 32.30 TOP RIGHT BOTTOM LEFT
b 1+0.03
a-b = x -
c 31 – 0.03
x – c =d 0.25 – 0.33
e 0.3 + 0.03
x-e = U1 31.00
115
HP MODULE DOCUMENTS
6.19 - HP TURBINE ASSEMBLY REFERENCE DIMENSIONS
MEASURE AS PER DRG. AS OBSERVED REMARKS

a 10.00
b 0.25 TO 0.33 TOP LEFT RIGHT BOTTOM
c
d 2 + 0.5
e NON STRESSED (X) MEASURED
PRE STRESSED (Y) CALCULATED REFER SHEET- 5
PRESTRESSED 1.0 TO 1.13 CALCULATED (X-Y)
116
HP MODULE DOCUMENTS
6.20 - H. P. INLET INSERT ASSY. (ASSEMBLY)
1.0 PRE-COMPRESSION OF U-SEAL RING OF HP INLET PIPE
NOMINAL VALUE CALCULATED VALUE

LHS
RHS
2.0 TIGHTNESS OF BREACH-NUT : Tightness of Breach-nut should be 32 mm after closing the joint surface
117
CHAPTER VII - IP MODULE
ASSEMBLY DOCUMENTS
118
IP MODULE ASSEMBLY DOCUMENTS
7.1 - IP TURBINE – INNER CASING (PARTING PLANE GAP)
1 2 3 4 5 6 7
8 9 10 11 12 13 14
POSITION MEASUREMENT “A” (inside or outside the casing)

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Loosely seated
Tightened cold
Tightened warm
MEASUREMENT “B” (with 0.04 mm feeler)
Loosely seated
Tightened cold
Tightened warm
119
7.2 - IP TURBINE – INNER CASING (OVALITY MEASUREMENT)
DIMENSION NOMINAL CONDITION POSITION

1 2 3 4 5
a Loosely
seated
Tightened
cold
Tightened
warm
b Loosely
seated
Tightened
cold
Tightened
warm
c Loosely
seated
Tightened
cold
Tightened
warm
NOTE : 1. Joint gap and ovality measurement should preferably be done together
2. Parting plane studs may be tightened upto +60% to minimize joint gap.
3. If joint gap is 1.5 mm or less with top half being loosely seated and nominal
dia does not fall below 1 mm max., no further ovality measurement need be
done.
4. If joint gap is 1.5 mm or less with top half being loosely seated and also b is
less than c, no further joint gap measurement need be done.
120
7.3 - RADIAL CLEARANCES AT GUIDE BLADES OF IP TURBINE (TS)
UPPER HALF / LOWER HALF

CLEARANCES AS PER DRG.
STAGE 1 – 11 = 0.9 mm
STAGE 12-20 = 1.0 mm
NOTE : The seal shall be numbered beginning from Turbine side for each stage
STAGE SEAL LEFT RIGHT STAGE SEAL LEFT RIGHT STAGE SEAL LEFT RIGHT
NO NO NO
20 1 13 1 6 1
2 2 2
3 3 3
19 1 12 1 5 1
2 2 2
3 3 3
18 1 11 1 4 1
2 2 2
3 3 3
17 1 10 1 3 1
2 2 2
3 3 3
16 1 9 1 2 1
2 2 2
3 3 3
15 1 8 1 1 1
2 2 2
3 3 3
14 1 7 1
2 2
3 3
121
7.4 - RADIAL CLEARANCES AT GUIDE BLADES OF IP TURBINE (GENERATOR SIDE)
UPPER HALF / LOWER HALF

CLEARANCES AS PER DRG.
STAGE 1 – 11 = 0.9 mm
STAGE 12-20 = 1.0 mm
NOTE : The seal shall be numbered beginning from Turbine side for each stage
STAGE SEAL NO LEFT RIGHT STAGE SEAL NO LEFT RIGHT STAGE SEAL NO LEFT RIGHT
1 1 8 1 15 1
2 2 2
3 3 3
2 1 9 1 16 1
2 2 2
3 3 3
3 1 10 1 17 1
2 2 2
3 3 3
4 1 11 1 18 1
2 2 2
3 3 3
5 1 12 1 19 1
2 2 2
3 3 3
6 1 13 1 20 1
2 2 2
3 3 3
7 1 14 1
2 2
3 3
122
7.5 - AXIAL CLEARANCES BETWEEN BLADES OF IP TURBINE LOWER HALF (TURBINE

SIDE)
DURING DISMANTLING / AFTER FINAL ASSEMBLY
CASING
CASING
3 2 1
b b
a a
ROTOR
ROTOR
AXIAL CLEARANCE OF MOVING BLADES (TS)

+ DIRTECTION (a) - DIRECTION (b)
SIDE
LEFT LEFT RIGHT
20 5.2 - - -
19 5.2 6.2
18 5.2 6.2
17 5.2 6.2
16 5.2 6.2
15 5.2 6.2
14 5.2 6.2
13 5.2 6.2
12 5.2 6.2
11 5.2 - - -
10 5.2 6.2
9 5.2 6.2
8 5.3 5.3
7 5.3 5.3
6 5.3 5.3
5 5.3 5.3
4 4.8 5.3
3 4.8 5.3
2 4.8 5.3
1 4.8 5.3
123
7.6 - AXIAL CLEARANCES BETWEEN BLADES OF IP TURBINE LOWER HALF

(GENERATOR SIDE)
DURING DISMANTLING / AFTER FINAL ASSEMBLY
CASING
CASING
a a
b b
1 2 3
ROTOR ROTOR
AXIAL CLEARANCE OF MOVING BLADES (TS)

+ DIRTECTION (a) - DIRECTION (b)
SIDE
LEFT RIGHT LEFT RIGHT
1 5.3 4.8
2 5.3 4.8
3 5.3 4.8
4 5.3 4.8
5 5.3 5.3
6 5.3 5.3
7 5.3 5.3
8 5.3 5.3
9 6.2 5.2
10 6.2 5.2
11 6.2 5.2
12 - 5.2
13 6.2 5.2
14 6.2 5.2
15 6.2 5.2
16 6.2 5.2
17 6.2 5.2
18 6.2 5.2
19 6.2 5.2
20 - 5.2
124
7.7 - AXIAL SEAL STRIP CLEARANCES OF MOVING BLADES OF IPT

MOV ING BLADES
TOL : +- 0.8
TURBINE SIDE GENERATOR SIDE

STAGE (-) DIRECTION (+) STAGE (-) DIRECTION (+)
NO AS PER AS OBSERVED AS PER AS OBSERVED NO AS PER AS OBSERVED AS PER AS OBSERVED
DRG LEFT RIGHT DRG LEFT RIGHT DRG LEFT RIGHT DRG LEFT RIGHT
20 3.8 4.6 1 3.6 4.8

19 3.8 4.6 2 3.6 4.8
18 3.8 4.6 3 3.6 4.8
17 3.8 4.6 4 3.6 4.8
16 3.8 4.6 5 3.6 4.8
15 3.8 4.6 6 3.6 4.8
14 3.8 4.6 7 3.6 4.8
13 3.8 4.6 8 3.6 4.8
12 3.8 4.6 9 4.4 7.0
11 3.8 4.6 10 4.4 7.0
10 3.8 4.6 11 4.4 7.0
9 3.8 4.6 12 4.4 7.0
8 3.8 4.6 13 4.4 7.0
7 3.8 4.6 14 4.4 7.0
6 3.8 4.6 15 4.4 7.0
5 3.8 4.6 16 4.4 7.0
4 3.8 4.6 17 4.4 7.0
3 3.8 4.6 18 4.4 7.0
2 3.8 4.6 19 4.4 7.0
1 3.8 4.6 20 4.4 7.0
125
AXIAL SEAL STRIP CLEARANCES OF MOVING BLADES OF IPT

GUIDE BLADES
TOL : +- 0.8
TURBINE SIDE GENERATOR SIDE

STAGE (-) DIRECTION (+) STAGE (-) DIRECTION (+)
NO AS PER AS OBSERVED AS PER AS OBSERVED NO AS PER AS OBSERVED AS PER AS OBSERVED
DRG LEFT RIGHT DRG LEFT RIGHT DRG LEFT RIGHT DRG LEFT RIGHT
20 5.0 4.4 1 3.4 6.0

19 5.0 4.4 2 3.4 6.0
18 5.0 4.4 3 3.4 6.0
17 5.0 4.4 4 3.4 6.0
16 5.0 4.4 5 3.4 6.0
15 5.0 4.4 6 3.4 6.0
14 5.0 4.4 7 3.4 6.0
13 5.0 4.4 8 3.4 6.0
12 5.0 4.4 9 3.4 6.0
11 5.0 4.4 10 3.4 6.0
10 5.0 4.4 11 3.4 6.0
9 5.0 4.4 12 3.4 6.0
8 5.0 4.4 13 3.4 6.0
7 5.0 4.4 14 3.4 6.0
6 5.0 4.4 15 3.4 6.0
5 5.0 4.4 16 3.4 6.0
4 5.0 4.4 17 3.4 6.0
3 5.0 4.4 18 3.4 6.0
2 5.0 4.4 19 3.4 6.0
1 5.0 4.4 20 3.4 6.0
126
7.8 - IP SHAFT SEALING RADIAL AND AXIAL CLEARANCES (TURBINE SIDE)
NOTE : The sealing strips shall be numbered successively beginning at turbine side:
Sealing RADIAL CLEARANCE “d” AXIAL CLEARANCES TOL :  0.5

Ring AS PER AS OBSERVED + DIRECTION (a) - DIRECTION (b)
DRG LEFT RIGHT DRG. LEFT RIGHT DRG. LEFT RIGHT
5 1 0.50 3.9 - - -
2 0.50 3.9 - - - - -
3 0.50 3.9 3.4
4 0.50 3.9 - - 3.4 - -
5 0.50 3.9 3.4
6 0.50 3.9 - - 3.4 - -
7 0.50 3.9 3.4
8 0.50 3.9 - - 3.4 - -
9 0.50 3.9 3.4
10 0.50 3.9 - - 3.4 - -
11 0.50 3.9 3.4
12 0.50 3.9 - - 3.4 - -
13 0.50 3.9 3.4
14 0.50 - - - - - -
127
IP SHAFT SEALING RADIAL AND AXIAL CLEARANCES

(TURBINE SIDE)

4 15 0.50 3.9 - - -
16 0.50 3.9 - - - - -
17 0.50 3.9 3.4
18 0.50 3.9 - - 3.4 - -
19 0.50 3.9 3.4
20 0.50 3.9 - - 3.4 - -
21 0.50 3.9 3.4
22 0.50 3.9 - - 3.4 - -
23 0.50 3.9 3.4
24 0.50 3.9 - - 3.4 - -
25 0.50 3.9 3.4
26 0.50 3.9 - - 3.4 - -
27 0.50 3.9 3.4
28 0.50 - - - - - -
3 29 0.50 3.9 - - -
30 0.50 3.9 - - - - -
31 0.50 3.9 3.4
32 0.50 3.9 - - 3.4 - -
33 0.50 3.9 3.4
34 0.50 3.9 - - 3.4 - -
35 0.50 3.9 3.4
36 0.50 3.9 - - 3.4 - -
37 0.50 3.9 3.4
38 0.50 3.9 - - 3.4 - -
39 0.50 3.9 3.4
40 0.50 3.9 - - 3.4 - -
41 0.50 3.9 3.4
42 0.50 - - - - - -
128

(TURBINE SIDE)

2 43 0.50 3.9 3.4 - -
44 0.50 3.9 - - 3.4 - -
45 0.50 3.9 3.4
46 0.50 3.9 - - 3.4 - -
47 0.50 3.9 3.4
48 0.50 3.9 - - 3.4 - -
49 0.50 3.9 3.4
50 0.50 3.9 - - 3.4 - -
51 0.50 3.9 3.4
52 0.50 3.9 - - 3.4 - -
53 0.50 3.9 3.4
54 0.50 3.9 - - 3.4 - -
55 0.50 3.9 3.4
56 0.50 - - - - - -
1 57 0.50 3.9 3.4 - -

58 0.50 3.9 - - 3.4 - -
59 0.50 3.9 3.4
60 0.50 3.9 - - 3.4 - -
61 0.50 3.9 3.4
62 0.50 3.9 - - 3.4 - -
63 0.50 3.9 3.4
64 0.50 3.9 - - 3.4 - -
65 0.50 3.9 3.4
66 0.50 3.9 - - 3.4 - -
67 0.50 3.9 3.4
68 0.50 3.9 - - 3.4 - -
69 0.50 3.9 3.4
70 0.50 - - - - - -
129
7.9 - IP SHAFT SEALING RADIAL AND AXIAL CLEARANCES (GENERATOR SIDE)

6 1 0.50 10.4 - - -
2 0.50 10.4 - - - - -
3 0.50 10.4 3.4
4 0.50 10.4 - - - - -
5 0.50 10.4 3.4
6 0.50 10.4 - - - - -
7 0.50 10.4 3.4
8 0.50 - - - - - -
7 9 0.50 10.4 3.4
10 0.50 10.4 - - 3.4 - -
11 0.50 10.4 3.4
12 0.50 10.4 - - 3.4 - -
13 0.50 10.4 3.4
14 0.50 10.4 - - 3.4 - -
15 0.50 10.4 3.4
16 0.50 -
130

(GENERATOR SIDE)

8 17 0.50 10.4
18 0.50 10.4 - -
19 0.50 10.4
20 0.50 10.4 - -
21 0.50 10.4
22 0.50 10.4 - -
23 0.50 10.4
24 0.50 - - -
9 25 0.50 10.4
26 0.50 - - -
27 0.50 10.4
28 0.50 - - -
29 0.50 10.4
30 0.50 - - -
31 0.50 10.4
32 0.50 - - -
10 33 0.50 10.4
34 0.50 - - -
35 0.50 10.4
36 0.50 - - -
37 0.50 10.4
38 0.50 - - -
39 0.50 10.4
40 0.50 - - -
131
7.10 - IP SHAFT SEALING (ASSEMBLY)
SEALING ‘a’ AS PER ‘a’ AS OBSERVED

SING DRG. SEGMENT
A –B B –C C –D D–E E- F F-A
5 0.1 – 0.27
4 0.1 – 0.27
3 0.1 – 0.27
2 0.1 – 0.27
1 0.1 – 0.27
6 0.1 – 0.27
7 0.1 – 0.27
8 0.1 – 0.27
9 0.1 – 0.27
10 0.1 – 0.27
132
IP SHAFT SEALING (ASSEMBLY)
TEST LOAD
DETAIL - I
AS PER A B C
DRG. 0 0.1 – 0.2 -
SEALING AS OBSERVED
NO. LEFT RIGHT LEFT RIGHT LEFT RIGHT
5
4
3
2
1
7
8
9
10
133
7.11 - MINIMUM RADIAL CLEARANCE IN THE BLADE SECTION OF IP

TURBINE (ASSEMBLY)
GUIDE BLADES
MOVING BLADES
MINIMUM CLEARANCE AS PER DRAWING :-

GUIDE BLADES (a) 0.9 mm
MOVING BLADES (b) 0.9 mm
ALIGNMENT
TS GS
RADIAL CLEARANCES AS OBSERVED
TS GS
TOLERANCE : ALIGNMENT 0.05 mm

RADIAL CLEARANCES > Nominal as per Drawing 0.15 mm
134
7.12 - MINIMUM AXIAL CLEARANCES AT THE SEALING STRIPS OF THE

GUIDE BLADES
+VE -VE
TOLERANCE = 0.7 mm
AXIAL DISPLACEMENT OF ROTOR IN AXIAL DISPLACEMENT OF ROTOR IN

LOWER PART OF CASING LOWER & UPPER PART OF CASING
MEASUREMENT
(WITHOUT SHAFT SEALS) (WITHOUT SHAFT SEALS)
AS PER DRG AS OBSERVED AS PER DRG AS OBSERVED
+ VE DIRECTION (a) 4.4 (a) 4.4
- VE DIRECTION (b) 3.4 (b) 3.4
TOTAL CLEARANCE (a+b) 7.8 (a+b) 7.8
135
7.13 - IP CASING ASSEMBLY JOINT FLANGE BOLTS – TIGHTENING &

ELONGATION
OBSERVED VALUES
Part No Nominal Gauge Elongation of Angle of Remarks
of Bolts Length Length Gauge Length Rotation of
Nut
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
136
7.14 - BOLTTIGHTNING OF IP CASING (OUTER)
BOLT NO. LOCATION BOLT SIZE NOMINAL L1 L2 L1-L2 =  L

L DESIGN
176 IP FRONT M 72 X 6 0.49
LEFT
175 IP FRONT M 72 X 6 0.49
RIGHT
174 IP REAR M 72 X 6 0.49
RIGHT
177 IP REAR M 72 X 6 0.49
LEFT
137
7.15 - IP CASING ASSEMBLY CLEARANCE MEASUREMENT (GENERATOR

SIDE)
h
c
e f

a > 7.0 LEFT RIGHT
b > 7.0 UPPER > LOWER > UPPER > LOWER >
c 0.25  0.30 UPPER > LOWER > UPPER > LOWER >
d > 7.0 UPPER > >
LOWER > >
e -
f 0.10  0.15
g -
h > 3.0 > >
i > 7.0 > >
j 0.15  0.20
138
7.16 - IP CASING ASSEMBLY CLEARANCE MEASUREMENT (TURBINE SIDE)
k
a
h f g h b
e
i i
d d
F F
C C

LEFT RIGHT
a 0.25  0.30
b 0.15  0.20
c 0.30  0.35 TS
GS
d > 7.0 UPPER > >
LOWER > >
e -
f 0.10  0.15
g -
h 2  1 TS > >
GS
i - TS > >
- GS
j > 7.0 > >
k > 3.0 > >
139
7.17 - IP CASING ASSEMBLY CLEARANCE MEASUREMENT
NOTE : THESE READINGS ARE REQUIRED IN CASE OF REPLACEMENT OF INNER OR OUTER CASING
MEASUREMENT AS PER DRG. AS OBSERVED

a > 7.0
b > 7.0
c > 7.0
140
CHAPTER VIII - DOCUMENTS
FOR GENERAL OVERHAUL
141
DOCUMENTS FOR GENERAL OVERHAUL
8.1 - LP AXIAL BLADE CLEARANCES

(DURING DISMENTLING/AFTER FINAL ASSEMBLY)
STATIONARY BLADE
STEAM FLOW
MOVING BLADE
TURBINE SIDE
AXIAL CLEARANCE BETWEEN BLADES
a b
AS PER
STAGE AS PER LEFT RIGHT DRG LEFT RIGHT
NO. DRG
DIS ASSY DIS ASSY DIS ASSY DIS ASSY
1 - 27
2 7 27
3 7 27
4 14 27
5 7 27
6 13.5 33.5
7 13.5 33.5
8 13 33
GENERATOR SIDE
AXIAL CLEARANCE BETWEEN BLADES
a b
AS PER
STAGE AS PER LEFT RIGHT DRG LEFT RIGHT
NO. DRG
DIS ASSY DIS ASSY DIS ASSY DIS ASSY
1 - 7
2 27 7
3 27 7
4 34 7
5 27 7
6 33.5 13.5
7 33.5 13.5
8 33 13
142
8.2 - LP RADIAL BLADE CLEARANCES

(DURING FINAL ASSEMBLY)
note: readings recorded are as measured before roll check,need not be repeated after roll check.
TURBINE SIDE
ROTOR BLADES STATIONARY BLADES

STAGE NO. NOMINAL
LEFT RIGHT NOMINAL LEFT RIGHT
8 10.6 1.5
7 6.7 1.5
6 2.5 1.5
5 1.5 1.5
4 1.5 1.5
3 1.5 1.5
2 1.5 1.5
1 1.5 1.5
GENERATOR SIDE
ROTOR BLADES STATIONARY BLADES

STAGE NO. NOMINAL
LEFT RIGHT NOMINAL LEFT RIGHT

1 1.5 1.5
2 1.5 1.5
3 1.5 1.5
4 1.5 1.5
5 1.5 1.5
6 2.5 1.5
7 3.3 1.5
8 5.4 1.5
143
8.3 - SEAL BORE READING

(BEFORE DISMANTLING/AFTER FINAL ASSEMBLY)
L R
LEFT RIGHT BOTTOM

LOCATION DISMNT. ASSY. DISMNT. ASSY. DISMNT. ASSY.
HPF
HPR
IPF
IPR
LPF
LPR
144
8.4 - LP ROTOR AXIAL LOCATION

(BEFORE DISMANTLING /AFTER FINAL ASSEMBLY)
PEDESTAL NO.3 PEDESTAL NO.4
LEFT RIGHT
LOCATION Dismantling Assembly Dismantling Assembly
FRONT
REAR
145
2 3
1 4
8 5
7 6
b b
146
8.5 - MAIN OIL PUMP ASSEMBLY CLEARANCES (ASSY)
NOMINAL ACTUAL
MEAS. MIN. CLEARANCE MAX. CLEARANCE CLEARANCE
a. FRONT BRG 0.060 0.110
b. IMP W.RING (F) 0.145 0.210
c. IMP W.RING (R) 0.145 0.210
d. THRT BRG FLT 0.180 0.221
e. THRT BRG CLR 0.060 0.110
f. GOP W.RING (F) 0.120 0.177
g. GOP W.RING (R) 0.120 0.177
MEAS. NOMINAL ACTUAL CLEARANCE
h. P0.50
i. P0.50
j.
k.
l.
m.
n.
o.
p.
q.
AXIAL-BEARING BOX,DRAWING NO.

MEAS. NOMINAL ACTUAL
SHOE. NO.
1 2 3 4 5 6 7 8
T.S.
G.S.
2 3 4 5 6 7
1
8 9
10 11
147
8.6 - MAIN OIL PUMP :SHAFT CONCENTRICITY CHECK

MEASURING POINT RUN OUT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
8.7 -MAIN OIL PUMP :COUPLING CLEARANCES
MEAS. NOMINAL `ACTUAL

a.
b.
c.
d.
e.
f.
148
8.8 - HYDRAULIC TURNING GEAR NOZLE BOX RADIAL AND AXIAL

CLEARANCES
II
I e b
C
a
a
DETAIL I
b
DETAIL II
ACTUAL
DIMENSION NOMINAL
DISMANTL ASSY
a. 3± 0.2
b. 0.30
c. 14 ± 0.50
d. 5 ± 0.50
e. 14 ± 0.50
149
8.9 - CLEARANCES OF BEARING SEAL STRIP

(DURING DISMANTLING/ FINAL ASSEMBLY)
DIS ASSY
HPF
DIS ASSY DIS ASSY
HPR IPF
DIS ASSY DIS ASSY
IPR LPF
DIS ASSY
LPR
150
8.10 - CLEARANCES Of OIL GUARD RING AT BEARING

(DURING DISMANTLING/ FINAL ASSEMBLY)
BEARIN ASS
G NO. DIS ASSY DIS Y
1
FRONT REAR
ASS
DIS ASSY DIS Y
2 FRONT REAR
ASS
DIS ASSY DIS Y
3
FRONT REAR
ASS
DIS ASSY DIS Y
4
FRONT REAR
ASS
DIS ASSY DIS Y
5
FRONT REAR
151
8.11 - BEARING CLEARANCES
THRUST FLO AT
f f O
e e
b
c c
B C e f a
D
DRAWINGS
(TOC)
BRG NO
FRONT REAR FRONT REAR

SHAFT DIA
A
g D
C
RIGHT
LEFT
A R
T
DRG C L R L R L R L R G
T
0.34 0.42
28
D 1 TO TO
0
I 0.41 0.45
S 0.35 0.43
29
M 2 TO TO
0
A 0.41 0.46
N 0.54 0.36
45
T 3 TO TO
0
L 0.62 0.40
I
N 0.48 0.32
40
G 4 TO TO
0
0.54 0.36
0.34 0.42
28
A 1 TO TO
0
S 0.41 0.45
S 0.35 0.43
29
0.3 ±
E 2 TO TO
0
0.1
M 0.41 0.46
B 0.54 0.36
45
L 3 TO TO
0
Y 0.62 0.40
0.48 0.32
40
4 TO TO
0
0.54 0.36
152
8.12 - RADIAL THRUST BEARING

(DURING DISMANTLING/AFTER FINAL ASSEMBLY)
BEARING
AXIAL KEY
A B
OS TS
TS OS
D1
E F
LEFT RIGHT
A
B
E
F
NOTE:A and B refer to measurement of gap at these locations.
RECORD OF PAD THICKNESSES
PADN 1 2 3 4 5 6 7 8 9 10 11 12 13 14
O.
TK
PADN 1 2 3 4 5 6 7 8 9 10 11 12 13 14
O.
TK
153
8.13 - SWING CHECK

(DURING DISMANTLING /AFTER FINAL ASSEMBLY)
THROW AT JOURNAL NO.1
HOLE OF HP/IP COUPLING
DISMANTLING ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
R/O
Note:
1) Readings are to be recorded after elongation of all coupling bolts of HP/IP and HP/LP
coupling.
2) Dial Indicator on Journal no. 1 is mounted on Parting Plane
3) Position of Hole(Left/Right) ,dial gauge position on Parting Plane (Left/Right) is to be
recorded.
4) JOP is to be stopped before each reading.
154
8.14 - ALIGNMENT
RADIAL AXIAL
MOP TOL : T-B= ± 0.02 mm
JOURNAL
L-R=± 0.02 mm RUN OUT
DISMANTLING ASSY.
AXIAL 1
TOL: T-B=0.3 ± 0.05 mm

L-R =± 0.04 mm
MOP shaft to be kept up w.r.t . H.P. rotor
HPR-IPR AXIAL 2
IPR-LPR AXIAL 3
LP-GEN
RADIAL AXIAL 4
155
8.15 - HP/IP JOURNAL AND COUPLING RUN - OUT

(RECORD FINAL VALUES AFTER COUPLING ALL THREE ROTORS)
HP COUPLING
BOLT NO. HP JOURNAL J2 IP COUPLING J1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
R/O
156
8.16 - IP/LP JOURNAL AND COUPLING RUN - OUT
BOLT NO. IP JOURNAL J3 IP COUPLING LP COUPLING LP ROTOR

J4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
R/O
157
8.17 - LP/GEN. JOURNAL AND COUPLING RUN OUT

J4 LPC GEN C J5
BOLT NO. LP JOURNAL J4 LP COUPLING GEN. GEN. GEN.

COUPLING JOURNAL J5 JOURNAL J6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
R/O
158
HP/IP COUPLING IP/LP COUPLING LP/GEN COUPLING

BOLT NO. AS PER δl BOLT AS PER δl BOLT AS PER δl
DRG. NO. DRG. NO. DRG.
1. 1
1
2.
2 2
3.
4. 3 3
5. 4 4
0.31
6. TO 5
5
0.34 6
7. 6
0.4 1
8. 7
7 TO 0.43
9. 0.43 8
8 TO
10. 9
0.47
11. 9 10
12. 10 11
13. 12
11
14. 13
12
15. 14
13 15
16.
14 16
17
18
159
8.18 - HP ROTOR FLOAT AND ROLLING TEST

D
C
CENTEREING OF CASING
ASS
DIS ASSY DIS
Y
FRONT REAR
RADIAL DISPLACEMENT ( ROLL CHECK)
ASS
DIS ASSY DIS
Y
FRONT REAR
AXIAL DISPLACEMENT OF ROTOR
DISPLACEMENT MEASURED ERECTION/SHOP

DISMANT. ASSY.
IN ‘+’ DIRECTION
IN ‘-’ DIRECTION
TOTAL DISPLACEMENT
160
8.19 - IP ROTOR FLOAT AND ROLLING TEST

C D
CENTERING OF CASING
C D
ASS
DIS ASSY DIS
Y
FRONT REAR
RADIAL DISPLACEMENT (ROLL CHECKING)
ASS
DIS ASSY DIS
Y
FRONT REAR
AXIAL DISPLACEMENT OF ROTOR
DISPLACEMENT MEASURED ERECTION/SHOP

DISMANT. ASSY.
IN ‘+’ DIRECTION
IN ‘-’ DIRECTION
TOTAL DISPLACEMENT
161
8.20 - LP ROTOR FLOAT AND ROLLING TEST

C D
MINIMUM RADIAL CLEARANCE OF GLAND BOX SEALS:
C D
ASS
DIS ASSY DIS
Y
FRONT REAR
RADIAL DISPLACEMENT (ROLL CHECK)
ASS
DIS ASSY DIS
Y
FRONT REAR
162
8.21 - HORN DROP TEST
HP CYLINDER
LOCATION DISMANTLING ASSEMBLY
HP FRONT LEFT
HP FRONT RIGHT
HP REAR LEFT
HP REAR RIGHT
IP CYLINDER
LOCATION DISMANTLING ASSEMBLY
IP FRONT LEFT
IP FRONT RIGHT
IP REAR LEFT
IP REAR RIGHT
Refer Document on “Instruction for Critical Activities)

(TS/ST-01/003) issued by TS-HQ
163
8.22 - CLAMPING BLOCKS CLEARANCES

BEARING
PEDESTAL
CLEARANCE ‘C’
CLAMPING PLATE
CLEARANCES - C
LOCATION AS PER DRG ACTUAL
HP FRONT RIGHT 0.1-0.15
HP FRONT LEFT 0.1-0.15
HP REAR RIGHT 0.1-0.15
HP REAR LEFT 0.1-0.15
IP FRONT RIGHT 0.1-0.15
IP FRONT LEFT 0.1-0.15
IP REAR RIGHT 0.1-0.15
IP REAR LEFT 0.1-0.15
164
8.23 - HP ROTOR STUB SHAFT RUN OUT
J1 S1 S2
BOLT NO J S1 S2
R/O
165
8.24 - JACKING OIL LIFT AT JOURNAL AND PRESSURE
HP IP LP GEN
B1 B2 B3 B4 B5 B6
LOCATION LIFT (mm) PRESSURE (Kg/Cm2)
B1
B2
B3
B4
B5
B6
HEADER PRESSURE AT MOT _____________ Kg/Cm2
166
8.25 - PEDESTAL L- CLAMP CLEARANCES
FRONT HP-IP
PEDESTAL PEDESTAL
MEASUREMENT A B C
AS PER DRG 56 50.6 0.50
RIGHT
LEFT
LOCATION
AS PER DRG 0.1 TO 0.15 0.1 TO 0.15
FRONT LEFT -
FRONT RIGHT -
REAR LEFT
REAR RIGHT
C
A B
DETAIL- I
A- UN TIGHTENED
B- TIGHTENED
167
8.26 - HP CASING AXIAL REFERENCE
TOP
MEASUREMENT
DISMANTLE ASSEMBLY
HP FRONT
HP REAR
168
8.27 - IP CASING AXIAL REFERENCE
IP CYLINDER
B
IP ROTOR
GS
TOP
MEASUREMENT
DISMANTLE ASSEMBLY
HP FRONT
HP REAR
169
8.28 - PROTECTIVE DEVICE CLEARANCES
LINK I
SHAFT POSITION MONITOR TS GS
NOMINAL 1± 0..1 mm 1± 0..1 mm
ACTUAL
LINK II
TS GS
NOMINAL 1± 0..1 mm 1± 0..1 mm
ACTUAL
LINK I
NOMINAL 2± 0.2 mm
ACTUAL
LINK II
NOMINAL 2± 0.2 mm
ACTUAL
EMERGENCY GOVERNOR
NOMINAL 1.5± 0..1 mm

LINK I
ACTUAL
NOMINAL 1.5± 0..1 mm

LINK II
ACTUAL
170
8.29 - HP STUB SHAFT RUN OUT
BOLT NO LEFT RIGHT
R/O
171
8.30 - JACKING OIL LEFT AT JOURNALS AND PRESSURE
HP IP LP GEN
B1 B2 B3 B4 B5 B6
LOCATION LIFT (mm) PRESSURE (Kg/cm2)

B1
B2
B3
B4
B5
B6
172
FREE CONDITION
TS GS
STAGE NO.
AA BB CC AA BB CC
AFTER COLD TIGHTENING
TS GS
STAGE NO.
AA BB CC AA BB CC
AFTER HOT TIGHTENING

TS GS
STAGE NO.
AA BB CC AA BB CC
173
CHAPTER IX - VALVES AND
GOVERNING
174
VALVES AND GOVERNING
9.1 - HP STOP & CONTROL VALVES CLEARANCES

HP CONTROL VALVE
VALVE CONE CUSH VALVE SPINDAL BUSH
SPINDAL BUSH CLR SPINDAL BUSH CLR
A
CV
B
1
C
AV
A
CV
B
2
C
AV
NOMINAL CLEARANCES
HP CV CONE BUSH 0.16 TO 0.195 MM
HP STOP VALVE
VALVE CONE CUSH VALVE SPINDAL BUSH
SPINDAL BUSH CLR SPINDA BU CLR
L SH
A
SV1 B
C
AV
A
SV2 B
C
AV
HP U- RING COMPRESSION
CV1
CV2
SV1
SV2
175
9.2 - IP STOP & CONTROL VALVES CLEARANCES

IP STOP VALVE
VALVE CONE BUSH VALVE SPINDAL BUSH
A
SV1 B
C
AV
A
SV2 B
C
AV
NOMINAL CLEARANCES
HP CV CONE BUSH 0.16 TO 0.195 MM
IP CONTROL VALVE
A
CV1 B
C
AV
A
CV2 B
C
AV
NOMINAL CLEARANCES
CONE BUSH (BOTH CV AND SV) 0.60 TO 00.68
176
9.3 - LP BYPASS STOP &CONTROL VALVES CLEARANCES

LP BYPASS STOP AND CONTROL VALVE
A
SV1 B
C
AV
A
SV2 B
C
AV
A
CV1 B
C
AV
A
CV2 B
C
NOMINAL CLEARANCES (CONTROL VALVE)

BUSH CONE: 0.26 TO 0.31 MM
BUSH SPINDLE : 0.26 TO 0.31 MM
177
REFERENCES
 BHEL OPERATIONS & MAINTANANCE MANUAL

 BHEL LOGSHEETS
 PLANT SECTION LOG BOOK
 SOP’s GIVEN BY OEM
 VARIOUS TECHNICAL CIRCULARS RECIEVED FROM OEM

A Bansod Maintenance Manual For Kwu Turbine

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A Bansod Maintenance Manual For Kwu Turbine

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MAINTENANCE MANUAL FOR KWU TURBINE

DR. ATUL BANSOD, Ph.D. (Maint. Management, Turbine Overhaul)

The purpose of this manual is to provide guidance to carry out

In addition, formats for various activities including measurements

Every effort has been made to make each turbine maintenance

Plant employees shall take responsibility of safety of machine &

This manual is one of the resources available for maintenance

HPT High Pressure Turbine

Before taking up the actual overhauling it is necessary to know the condition

1.1 - OPERATING PARAMETERS OF 210/250/500 MW KWU TURBINE

8. HRH steam pressure Kg/cm2

10. Ist Stage Pressure Kg/cm2

12. Condenser Vacuum Kg/cm2

1.2 - TURBOVISORY READING

1.3 - TURBINE METAL TEMPERATURE

S.NO. DESCRIPTION UNITS VALUE

3. HP Casing metal Ti/Tm C

4. IP Casing metal Ti.Tm C

7. HP Top / Bottom Temperature C

8. IP Top / Bottom Temperature C

1.4 - LUB OIL SYSTEM PARAMETERS

S.NO. DESCRIPTION UNITS VALUE

3. Lub oil temperature after cooler C

4. MOP suction / discharge pressure Kg/cm2

1.5 - CW SYSTEM PARAMETERS

S.NO. DESCRIPTION UNITS VALUE

1. Condenser CW water inlet temperature C

2. Condenser CW water outlet temperature C

3. Condenser CW water inlet pressure Kg/cm2

4. Condenser CW water outlet pressure Kg/cm2

1.6 - AUXILIARY STEAM SYSTEM PARAMETERS

S.NO. DESCRIPTION UNITS VALUE

2. Gland steam temperature 0

3. Gland steam / Leak off steam controller position %

5. Auxiliary steam temperature 0

7. Steam temperature to ME (in case ME is there) 0

REGENERATIVE CYCLE PARAMETER

1.7 - CONDENSATE EXTRACTION PUMP

S.NO. DESCRIPTION UNITS VALUE

2. CEP discharge header pressure Kg/cm2

3. CEP discharge header temperature 0

4. CEP A/B/C Current Amp

5. Condensate flow TPH

1.8 - MAIN EJECTOR AND GSC

S.NO. DESCRIPTION UNITS VALUE

1.9 - CONDENSATE CYCLE

1.10 - BOILER FEED PUMP

S.NO. DESCRIPTION UNITS VALUE

1.11 - FEEDWATER CYCLE

S.NO. DESCRIPTION UNITS VALUE

2. HPH-5 outlet temperature C

3. HPH-6 outlet temperature C

4. HPH-5 drip temperature C

5. HPH-6 drip temperature C

6. Extraction no. 5 pressure Kg/cm2

8. Extraction no. 6 pressure Kg/cm2

1.12 - BEARING METAL TEMPERATURE

Units Metal temperature Drain oil temperature

1.13 - BEARING VIBRATION

1.14 - CONTROL ROOM VIBRATION

1.15 - JACKING OIL PRESSURE

DESCRIPTION UNITS VALUE