ABSTRACT

This document explains the torquing and tensioning

required for the bolts of the outer and exhaust casings
of the Plant-II Turbines.

TURBOTRAINS
BOLTS
Prepared by: Sannay Muhammad
TK-431, TK-441, TK-01 and TK-421
Reviewed by: Wad, NDB
Plant-II Turbotrains
There are four turbo trains existing for Ammonia-III and Urea-III plants. This document specifies the basic
information required for the overhauling of the four machines.

1. TK-431
TK-431 is a special purpose GE condensing Steam Turbine driving the LP and HP Synthesis Gas
Compressors. The specifications for TK-431 are given below:

1.1 TK-431 Specifications

Model GE SAC 1 – 8

Rated Power 28840 kW

Maximum Continuous Speed 8786 rpm

Inlet Pressure 114 kg/cm2

Extraction Pressure 45.4 kg/cm2

Exhaust Pressure 0.22 kg/cm2

1.2 TK-431 Outer Casing Bolts

There are 22 tensioning (heating) bolts (Appendix 2) in the Syn Turbine. Their information is given below.
Refer to figure 1 for a schematic of the outer casing and POS. of the bolts.

Bolts Size Elongation Nut Rotation

Bolts Length
POS. (Nominal Dia x upon heating Allowance Required (Arc
(mm)
Pitch) (mm) of Tan)

1 72 x 6 620 0.70 0.105 58°

2–6 100 x 6 840 1.23 0.065 125°

7 90 x 6 520 0.75 0.110 62°

8 80 x 6 520 0.74 0.105 63°

9 80 x 6 520 0.75 0.110 65°

10 – 11 80 x 6 520 0.85 0.130 72°

 2 1 1 2

3 3
4 4

5 5

6 6

7 7

8 8

9 9
10 10

11 11

Figure 1: Outer casing of TK-431.

As per GE recommendations, the tensioning bolts can be heated to 250°C for installation and removal of
the bolts. But because of the manufacturing tolerances, repeated heating, and installation accuracies, the
bolts can be loosened or tightened at a range of temperatures from 120°C to 180°C. Ideally, a device
known as Extensometer is used to monitor the elongation of the bolts while heating and elongation
provided by GE is utilized. However, in case an Extensometer is not available, the Angle of Rotation of the
nut (arc of tan) can be used to achieve the required clamping force on the casing.

For installation of the bolts, the GE practice is to use the thermal expansion of the bolts as they are heated
using bolt induction heaters and measuring the elongation lengths of the bolts using an extensometer.

1.3 TK-431 Exhaust Casing Bolts

There are 34 (17 on each side) torquing bolts that lock the upper and lower halves of the exhaust casing of
the syn turbine. The sizes of the bolts and the applicable torques are given below:
 4 5 6 7 8
3 9
10
2
11
1
12
Not available in TK-431 14 13
16 15

17

Figure 2: TK-431 Exhaust Casing

Recommended
POS Nominal Diameter
Torque x1010 Nm (lb- in)

1 – 13 M42 362 ± 12 (2670 ± 88)

14 – 17 M36 225 ± 10 (1660 ± 74)

2. TK-441
TK-441 is a special purpose GE Steam Turbine driving the Refrigeration loop compressor. The
specifications for TK-441 are given below:

Model GE SAC 1 – 4

Rated Power 4930 kW

Maximum Continuous Speed 8981 rpm

Inlet Pressure 114 kg/cm2

Exhaust Pressure 0.196 kg/cm2

Extraction Pressure 45.4 kg/cm2

2.1 TK-441 Outer Casing Bolts

There are 10ea tensioning (heating) bolts and 12ea torquing bolts in the outer casing of the turbine. As per
GE recommendations, the tensioning bolts can be heated to 250°C for installation and removal of the

2 1
3
4

6
7
8

9
10

11

Figure 3: TK-441 Outer Casing

bolts. But because of the manufacturing tolerances, repeated heating, and installation accuracies, the
bolts can be loosened or tightened at a range of temperatures from 120°C to 180°C. Ideally, a device
known as Extensometer is used to monitor the elongation of the bolts while heating and elongation
provided by GE is utilized. However, in case an Extensometer is not available, the Angle of Rotation of the
nut (arc of tan) can be used to achieve the required clamping force on the casing.

The details for the tensioning bolts are given below:

Elongation Nut Rotation

Bolts Length
POS. Bolts Size upon heating Allowance Required (Arc
(mm)
(mm) of Tan)

2–6 M60 530 0.8 0.05 72°

The details for the torquing bolts are as follows:

Recommended
POS Nominal Diameter
Torque x1010 Nm (lb- in)

1 M42 362 ± 12 (2670 ± 88)

7 – 11 M42 362 ± 12 (2670 ± 88)

2.2 Exhaust Casing Bolts

All the bolts in the exhaust casing are of the torquing types. The details of the bolts are given below:

4
11
3 5 6 7 8 9 10
12
2
13
1
14
17 15
16

18
5

Figure 4: TK-441 Exhaust Casing

Recommended
POS Nominal Diameter
Torque x1010 Nm (lb- in)

1 – 18 M24 60 ± 3 (443 ± 22)

3. TK-01
TK-01 is the third GE turbine situated at the Urea-3 plant and drives the LP and HP CO2 compressors. The
specifications of the turbine are given below.

Model GE SAC 1 – 8

Rated Power 15590 kW

Maximum Continuous Speed 7017 rpm

Inlet Pressure 114 kg/cm2

Exhaust Pressure 0.10 kg/cm2

Extraction Pressure 24.5 kg/cm2

Induction Pressure 3 kg/cm2

3.1 TK-01 Outer Casing Bolts

The turbine has 12 ea Tensioning (heating) bolts and 20 ea Torquing bolts in the outer casing. There are
10ea tensioning (heating) bolts and 12ea torquing bolts in the outer casing of the turbine. As per GE
recommendations, the tensioning bolts can be heated to 250°C for installation and removal of the bolts.
But because of the manufacturing tolerances, repeated heating, and installation accuracies, the bolts can
be loosened or tightened at a range of temperatures from 120°C to 180°C. Ideally, a device known as
Extensometer is used to monitor the elongation of the bolts while heating and elongation provided by GE is
utilized. However, in case an Extensometer is not available, the Angle of Rotation of the nut (arc of tan) can
be used to achieve the required clamping force on the casing.

4 5 6
3 11 12 13
16
2 14 15
7 8 9 10

Figure 5: TK-01 Outer Casing

 Elongation Nut Rotation
Bolts Length
POS. Bolts Size upon heating Allowance Required (Arc
(mm)
(mm) of Tan)

2–6 M80 685 1.0 0.05 94°

7 M72 370 0.55 0.08 48°

The details for the torquing bolts are given below:

Recommended Torque
POS Nominal Diameter
x1010 Nm (lb- in)

1 M56 891 ± 45 (6572 ± 332)

8 – 16 M64 1356 ± 70 (10000 ± 516)

4. TK-421
TK-421 turbine is used to drive the LP and HP Air compressors. The specifications for the turbine are:

Model ManTurbo AG

Rated Power 15590 kW

Rated Speed 6300 rpm

Inlet Pressure 44 kg/cm2

Exhaust Pressure 0.20 kg/cm2

4.1 TK-421 Bolts

The bolts on the casing of the TK-421 are of both torquing and hydraulic types. The details of the bolts are
given below:

25
21
23 17 7 1 9 13
19 11 3 5 15
Exhaust End Steam Inlet End

6 4 14 16
12
20
2 10
24 18 8
22
26

Figure 6: TK-421 Casing Bolts sequence and arrangement.

Recommended
POS Type
Hydraulic Pressure
Step 1: 300 bar
1 – 14 Hydraulic
Step 2: 500 bar
Step 1: 300 bar
15 – 16 Hydraulic
Step 2: 520 bar
Step 1: 350 bar
17 – 24 Hydraulic
Step 2: 575 bar
Step 1: 300 Nm
25 – 26 (38 ea) Torquing
Step 2: 510 Nm

For the hydraulic bolts, the bolting sequence is in the sequence indicated in the drawing i.e. from 1 to 24.
For the M30 end bolts. The torquing sequence is from center to outwards on opposite sides.
Appendix – 1: Bolting Sequence for GE Turbines
The GE turbines follow a bolting sequence of from the center towards the steam inlet side, and then from
the center towards the exhaust side, all the while alternating between the left and the right sides of the
casings. The general sequence of the bolts is given below:
Appendix 2: Tensioning and Torquing Bolts

The ultimate goal in bolting is to achieve the correct fastener preload (also known as bolt load or axial load).
Bolt torque and bolt tensioning are both legitimate ways to seal a joint. Bolt torquing exerts a rotational
force on the fastener, while bolt tensioning involves stretching a fastener with what looks like a hydraulic
load cell.

Torquing is the most commonly used way to achieve fastener preload with bolted joints. Torquing
produces this load through rotational force on a nut or bolt head. This torque is usually measured in foot-
pounds (ft-lbs.) or Newton-meters (Nm).

bolt or stud tensioning produces axial load by pulling up on a fastener with what looks like a hydraulic load
cell. Because tensioning does not place a twisting force on the fastener as applied torque does, we see
tensioners used with long threaded fasteners and on rotating equipment such as reciprocating rods.
Another good use of tensioning is large bolt diameters. On large bolt diameters, tensioning will save you
time compared to using hydraulic torque wrenches. Tensioning is more precise than torquing.