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  1. 1. GUJARAT TECHNOLOGICAL UNIVERSITY SIR BHAVSINHJI POLYTECHNIC INSTITUTE BHAVNAGARDEPARTMENT OF FABRICATION TECHNOLOGY L&T MHI TURBINE GENERATORS
  2. 2. PREPARED BY:1. MILAN J. VISANI (096490355031)2.CHIRAG P. GOHIL (096490355057)3. BHUPENDRA SOLANKI (096490355201)4. CHHATRAPAL RANA (096490355038) L&T MHI TURBINE GENERATORS
  3. 3. MAJOR REPORT ONGENERATOR STATOR FRAME
  4. 4. PROJECT NAME: MAHAGENCO-3.PART NAME: STATOR FRAME.DROWING NO: A11M430STAGE FOR PRODUCTION: FABRICATIONMANUFACTURE: L&T HAZIRA, SURATMATERIAL: SS 400 JIS IS 2062 gr A/B L&T MHI TURBINE GENERATORS
  5. 5. L&T MHI TURBINE GENERATORS
  6. 6. Introduction ToSteam Turbine L&T MHI TURBINE GENERATORS
  7. 7. INDEX •Steam Turbine Basics • Main component/assemblies/ systems of steam turbine •Major Sources of Producing Electricity • Principles of Electricity generation •Working principal of steam turbine •Supercritical technology •Turbine by-pass system •Major Components used In Turbine •Shop weld plan •Test plan •Quality control plan •Bill of material •Stator frame model fabrication sequence procedure •Box plot plan of generator stator frame •Process planning sheet •Some specific terms used in WPS •WPS •Functions of generator stator frame L&T MHI TURBINE GENERATORS
  8. 8. STEAM TURBINE LP TURBINEGENERATOR HIP TURBINE L&T MHI TURBINE GENERATORS
  9. 9. STEAM TURBINE HP PEDESTAL CROSS OVER PIPE RSV&ICV (Reheat Stop Valve) (Interceptor Valve) MSV&GV (Main Stop Valve) (Governing Valve) L&T MHI TURBINE GENERATORS
  10. 10. HIP TURBINEHIP OUTER CASING HIP ROTOR (UPPER) HIP OUTER CASING (LOWER) L&T MHI TURBINE GENERATORS
  11. 11. HIP TURBINEGO TO LP TURBINE MAIN STEAM INLET REHEAT STEAM INLET L&T MHI TURBINE GENERATORS
  12. 12. Generator Stator Assembly L&T MHI TURBINE GENERATORS
  13. 13. Electricity is thekey ingredient for thedevelopment of a nation L&T MHI TURBINE GENERATORS
  14. 14. Hydro Power Plant Thermal Power PlantPrime mover is Hydro Turbine Prime mover is Steam Turbine Rotated by energy of flowing Rotated by steam produced in Water supplied from Dam boiler by burning fossil fuels / reservoir L&T MHI TURBINE GENERATORS
  15. 15. Nuclear Power Station Gas based Power StationPrime-mover is Steam Turbine rotated Prime- mover is Gas Turbine run byby steam produced in Steam Generator air gas mixture ignited in combustionby Nuclear fission in the reactor. chamber L&T MHI TURBINE GENERATORS
  16. 16. World Power generation scenarioThermal Power Plant are most popular way for producingelectricity on large scale and will remain major source ofpower generation in foreseeable future due to relatively •Low capital cost •Shorter gestation time •Easy availability of fuel •Competitive generating cost •Reasonable high level of operating availability L&T MHI TURBINE GENERATORS
  17. 17. Power generation scenario in India 11 3 Thermal Hydro Nuclear 27 58 Gas. Major share in installed capacity and planned in future is thermal L&T MHI TURBINE GENERATORS
  18. 18. L&T MHI TURBINE GENERATORS
  19. 19. Thermal Power Plant L&T MHI TURBINE GENERATORS
  20. 20. Working Principal Of Steam TurbineNozzle Plate Force ‘F’ FCHANGE IN MOMENTUM = m x v – m x 0 =mxv L&T MHI TURBINE GENERATORS
  21. 21. Working Principal Of Steam Turbine V Force ‘F’ -VCHANGE IN MOMENTUM = (m x v) – (- m x v) = 2 x (m x v) Force ‘F’ α 2 x (m x v) L&T MHI TURBINE GENERATORS
  22. 22. Working Principal Of Steam Turbine v v sinθ θ v cosθ F-v cosθ CHANGE IN MOMENTUM = (mvcosθ) – (- mvcos θ) θ -v = 2 x (mvcos θ) -v sinθ Force ‘F’ α 2 (mvcos θ) L&T MHI TURBINE GENERATORS
  23. 23. WORKING PRINCIPLE OF STEAM TURBINE ROTATING •Steam at high pressure & temperature is made to pass BLADE ROW through a set of fixed blade mounted on stationary body in Casing. •There will be drop in pressure of the steam across the fixed blade resulting to very high steam velocity at the FIXED exit of fixed blade BLADE ROW •The high velocity steam then passes through another DRIVING row of blades mounted on the rotor shaftSTATIONARY FORCEBODY/CASING •The impingement of high velocity steam generates driving force on these rotating blades which rotate the rotor. • A set of fixed blades and rotating blades mounted on rotor is called stage of turbine. Depending on steam condition and power output, number of stages in steam turbine is decided L&T MHI TURBINE GENERATORS ROTOR
  24. 24. Main Components of Steam Turbine 1 2 3 4 5 6 7 1 1 81. Fixed/Guide Blades 5. Gland seals 9. Governing System2. Moving Blades 6. Bearing & bearing Pedestal 10.Lub. System3. Casing 7. Coupling 11.Drain system4. Rotor 8. Stop & Control Valves 12. C&I System L&T MHI TURBINE GENERATORS
  25. 25. Rotor is vital element involved inconversion of kinetic energy ofsteam into mechanical energy ofrotation.Run at high speed depending upongrid frequency (50Hz,60 Hz).Subjected to sever stresses i.e.Centrifugal forces, thermal L&T MHI TURBINE GENERATORS
  26. 26. Turbine By-Pass System L&T MHI TURBINE GENERATORS
  27. 27. Generator stator frame L&T MHI TURBINE GENERATORS
  28. 28. SHOP WELD PLAN Welding engineering department issues shop weld plan to Planning, Shop floor where actual job is going on. The name self indicate that it is a welding plan of actual job – vessel and it guides to shop floor supervisor and welder that which WPS/PQR shall use for particular seam. Shop welding plan is related to the welding of the job. It provided all the information regarding weld seam to the welder, as he must well aware of all required conditions of the welding each seam. If company is working under ISO-9000. It has to keep all the activities to be documented Hence the required documents are made. L&T MHI TURBINE GENERATORS
  29. 29.  SWP gives the following information regarding the job as related they all seem to be welded. ◦ Seam numbers ◦ Base metal / P-Number ◦ Joint Detail ◦ Weld process ◦ Layer ◦ WPS No. ◦ PQR No. ◦ F - Number ◦ Pre heat temperature ◦ Inter pass temperature ◦ Position ◦ Customer ◦ Inspection agency ◦ Mfg. Code ◦ Post weld heat treatment ◦ Special notes. L&T MHI TURBINE GENERATORS
  30. 30. TEST PLAN Welding engineering department issues test plan to planning, NDT, and shop floor for a particular job which is under production. In testing plan list of test for particular seam number is given with reference of ASME and customer specification and also given detail of production weld test coupon such as type of testing (destructive & Non- destructive), quantity thickness, For which seam no. required the PTC that is also described. After completion of welding of all seams particular test is carried out as per testing plan. With reference of Test plan the shop supervisor is offered the seam for testing to NDT department. L&T MHI TURBINE GENERATORS
  31. 31.  The following manners are given in the test plan: • Seam wise stage no. and stage description. For testing. • Extent • Specification • Acceptance standard • Production Test Coupon o Seam No, o Thickness o NDT o Chem. Analysis. o Transverse tensile’ o All weld tensile o Impact test o Micro/Macro test • Hardness • Inspection agencies Hydraulic/pneumatic/leak test and other tests TURBINE GENERATORS L&T MHI
  32. 32. QUALITY CONTROL PLAN QUALITY CONTROL PLANOrder: MODEL Drawing No.: Control No.: RJ/GEN/QAP-043Part No: As per drawing Part Name: GENERATOR STATOR FRAME Dt. 10.06.211QC Flow Chart Type : Project Items Project Name : Generator Stator Frame Ref. Doc.: Nil Manufacturing Relevant Sr. L&T MHI and Inspection Control Item Document And Frequency Supplier QC Sign Quality Record Remarks No. TG Process Procedure T-Side Block Assy (A42B327)1 Receiving Mill Sheet Visual Purchase 100% W R/W Mill TC Material All plates shall be inspection and & Dimension Specification As identification UT tested as material per drawing JV record mentioned in JV conformation Standard std. & identification (P. No etc. must be there)**2 Fit-up & Groove shape, As per drawing 100% W W Fit Up Report All line items as marking Angle, per drawing no. inspection Misalignment, A42B327 shall be Cleaning (Groove inspected at this Surface) stage.3 Welding Welder, Welding ASME Sec. IX 100% W … … Welding spatters, electrode, A35G107 A- under cut etc. Preheating, KOSHI-R04702 must not be there. Current/voltage4 PT test of Flaw detection A-SIKI- 100% W W PT Report For PT, Solvent completed weld method, ROWB007 removal method Situation of flaw shall be applied detection surface5 Dimensional & Visual, As per drawing 100% W W Dimensional visual Dimension, Report inspection Surface roughness L&T MHI TURBINE GENERATORS
  33. 33. E-Side Block Assy (A42B326)6 Receiving Mill Sheet Visual Purchase 100% W R/W Mill TC Material All plates shall be inspection and & Dimension Specification identification UT tested as material As per record mentioned in JV conformation drawing JV std. & Standard identification (P. No etc. must be there)**7 Fit-up & Groove shape, As per 100% W W Fit Up Report All line items as marking Angle, drawing per drawing no. inspection Misalignment, A42B327 shall be Cleaning (Groove inspected at this Surface) stage.8 Welding Welder, Welding ASME Sec. IX 100% W … … Welding spatters, electrode, A35G107 A- under cut etc. Preheating, KOSHI- must not be Current/voltage R04702 there.9 PT test of Flaw detection A-SIKI- 100% W W PT Report For PT, Solvent completed method, Situation ROWB007 removal method weld of flaw detection shall be applied surface10 Dimensional & Visual, As per 100% W W Dimensional visual Dimension, drawing Report inspection Surface roughness L&T MHI TURBINE GENERATORS
  34. 34. Centre Block Assy (A35F896)11 Receiving Mill Sheet Visual Purchase 100% W R/W Mill TC Material All plates shall be inspection and & Dimension Specification identification UT tested as material As per record mentioned in JV conformation drawing JV std. & Standard identification (P. No etc. must be there)**12 Fit-up & Groove shape, As per 100% W W Fit Up Report All line items as marking Angle, drawing per drawing no. inspection Misalignment, A42B327 shall be Cleaning (Groove inspected at this Surface) stage.13 Welding Welder, Welding ASME Sec. IX 100% W … … Welding spatters, electrode, A35G107 A- under cut etc. Preheating, KOSHI- must not be Current/voltage R04702 there.14 PT test of Flaw detection A-SIKI- 100% W W PT Report For PT, Solvent completed method, Situation ROWB007 removal method weld of flaw detection shall be applied surface15 Dimensional & Visual, As per 100% W W Dimensional visual Dimension, drawing Report inspection Surface roughness L&T MHI TURBINE GENERATORS
  35. 35. Frame Block Docking Assy (A35G121)16 Receiving Mill Sheet Visual & Purchase 100% W R/W Mill TC Material All plates shall be inspection and Dimension Specification As identification UT tested as material per drawing JV record mentioned in JV conformation Standard std. & identification (P. No etc. must be there)**17 Fit-up & Groove shape, As per drawing 100% W W Fit Up Report All line items as marking Angle, per drawing no. inspection Misalignment, A42B327 shall be Cleaning (Groove inspected at this Surface) stage.18 Welding Welder, Welding ASME Sec. IX 100% W … … Welding spatters, electrode, A35G107 A- under cut etc. Preheating, KOSHI-R04702 must not be there. Current/voltage19 PT test of Flaw detection A-SIKI- 100% W W PT Report For PT, Solvent completed weld method, Situation ROWB007 removal method of flaw detection shall be applied surface20 Final Visual, Dimension, As per drawing 100% W W Dimensional Dimensional & Surface roughness Report visual inspection21 Surface coating Type of coat, As per drawing 100% W R Painting Report & painting coating thickness and Specification Abbreviation :- W- Witness R- Review This quality control flow chart & QCL shall be revised as an when required. Prepared By Checked By Approved By L&T MHI TURBINE GENERATORS
  36. 36. BILL OF MATERIAL BILL OF MATERIAL PROJECT NAME:- GENERATOR STATOR FRAME Unit TotalSr Part THK in Qty Description Material Weight Weight RemarksNo. No. mm unit (Kg) (Kg)1 001 Shell Plate 5 SS400P 4 11.50 46.002 002 Cooler Adapter 10 SS400P 2 4.8 9.503 003 Lead box 10 SS400P 1 5.40 5.404 004 Frame Foot 10 SS400P 4 1.25 5.005 005 Frame Foot Support 1 8 SS400P 8 0.075 0.066 006 Frame Foot Support 2 8 SS400P 12 0.042 0.507 007 End Plate 10 SS400P 2 2.5 5.008 008 Rib Plate 10 SS400P 2 1.75 3.509 009 Flange 10 SS400P 6 0..67 0.4010 010 Trunion 10 SS400P 4 0.25 1.0011 011 Man hole 10 SS400P 4 1.25 5.0012 012 support 10 SS400P 4 2.5 10.0013 013 Bore Ring 8 SS400P 6 0.083 2.5014 014 Boring Support 10 SS400P 4 0.025 0.1015 015 Lifting Lug 10 SS400P 4 0.0375 0.15Total Weight 97.24 L&T MHI TURBINE GENERATORS
  37. 37. STATOR FRAME MODELFABRICATION SEQUENCE PROCEDURE Stator Frame Model fabrication Sequence Procedure Sr. Description Planned Date Actual Date Remarks No.1 Material Selection 5/3/2012 6/3/20122 Marking Of Shell 6/3/2012 8/3/20123 Long Seam Marking 7/3/2012 10/3/20124 Long Seam Welding On Shell 7/3/2012 10/3/20125 Circ. Seam Marking 8/3/2012 10/3/20126 Circ. Seam Welding On Shell 8/3/2012 11/3/20127 Gas Cutting Of T-Side And E-Side 9/3/2012 12/3/20128 Grinding Of Cutting Parts 10/3/2012 13/3/20129 Cnc Cutting Of E-Side And T-Side Parts 12/3/2012 153/201210 Grinding Of E-Side And T-Side Parts 13/3/2012 15/3/201211 Cnc Cutting Of Flanges, Manhole, Trunnion 14/3/2012 16/3/201212 Grinding Of Flanges, Manhole, Trunnion 14/3/2012 18/3/201213 Marking Of Bore Ring And Rib Plates 15/3/2012 19/3/201214 Cnc Cutting Of Bore Ring And Rib Plates 16/3/2012 20/3/201215 Grinding Of Bore Ring And Rib Plates 19/3/2012 21/3/2012 L&T MHI TURBINE GENERATORS
  38. 38. 16 Set-Up And Assembly Of E-Block Parts 20/3/2012 22/3/201217 Welding Of E-Block Parts 21/3/2012 23/3/201218 Set-Up And Assembly Of T-Block Parts 22/3/2012 24/3/201219 Welding Of T-Block Parts 23/3/2012 24/3/201220 Full Welding Of E-Block With Shell 24/3/2012 24/3/201221 Full Welding Of T-Block With Shell 24/3/2012 27/3/201222 Marking Of outer Components On Shell 26/3/2012 27/3/201223 Gas Cutting Of Components 27/3/2012 28/3/201224 Assembly Of Bore Ring And Rib Plates 28/3/2012 28/3/201225 Horizontal Docking Of Structure 29/3/2012 29/3/201226 Tack Weld Of Structure 29/3/2012 29/3/201227 Full Welding Of Structure With Shell 29/3/2012 30/3/201228 Fit-Up Of Outer Components 30/3/2012 30/3/201229 Welding Of Components 31/3/2012 2/4/201230 Marking Of Frame Foot And Its Supports 31/3/2012 2/4/201231 Welding Of Frame Foot And Its Supports 31/3/2012 3/4/201232 End Plate Fit-Up 2/4/2012 3/4/2012 L&T MHI TURBINE GENERATORS
  39. 39. 33 End Plate Welding 2/4/2012 4/4/201234 Visual Inspection 2/4/2012 4/4/201235 Distortion Removal 3/4/2012 4/4/201236 Dimension Checking 4/4/2012 4/4/201237 Cleaning And Surface Preparation 4/4/2012 4/4/201238 Marking Of Supports 5/4/2012 5/4/201239 Leveling Of Stator Frame 5/4/2012 5/4/201240 Welding Of Supports 5/4/2012 5/4/201241 Visual Inspection 5/4/2012 6/4/201242 Cleaning And Surface Preparation 5/4/2012 7/4/201243 Blasting 6/4/2012 9/4/201244 Painting 6/4/2012 10/4/201245 Final Inspection 7/4/2012 11/4/201246 Packing 9/4/2012 11/4/201247 Dispatch 10/4/2012 12/4/2012 L&T MHI TURBINE GENERATORS
  40. 40. BOX PLOT PLAN OF GENERATOR STATOR FRAME Drawing Material CNC cutting of Fit-up E-BLOCK Fabrication 7/3/2012 Selection parts and assembly 8/3/2012 grinding 16/3/2012 14/3/2012 BOX PLOT PLAN OF GENERATOR T-BLOCK Fit-up STATOR FRAME MODEL Fabrication Drawing Material CNC cutting Selection assembly 7/3/2012 of parts and 8/3/2012 17/3/2012 grinding 14/3/2012 Full Welding of Gas cutting Final Fit-up Outer Parts C-BLOCK Material of Shell, of E and T- Full Welding 28/3/2012 Support Fabrication Drawing Selection Marking of 24/3/2012 cutting and Grinding on block 7/3/2012 8/3/2012 E and T cutting part welding 18/3/2012 block side 17/3/2012 7/4/2012 12/3/2012 Inner side Marking of Vertical Fabrication Drawing Borering CNC cutting Assembly of Final Fit Of of Borering and 7/3/2012 and Rib of Borering Borering and Parts Rib plate plate and Rib plate 18/3/2012 Blasting 8/3/2012 Rib plate 9/4/2012 16/3/2012Flanges/ manhole/ CNC Material Marking on trunnion Drawing cutting of shell Fit-up on Painting Selection Fabrication 7/3/2012 external 9/4/2012 8/3/2012 21/3/2012 shell items 22/3/2012 16/3/2012 Frame foot/End Material Drawing Selection CNC cutting Marking, Fit-up Packing plate 7/3/2012 8/3/2012 of external Set-up 24/3/2012 10/4/2012 Fabrication items 22/3/2012 19/3/2012 FABRICATION HRS: 34 DAYS Dispatch TOTAL WEIGHT: 97.24 KGS 10/4/2012 L&T MHI TURBINE GENERATORS
  41. 41. PROCESS PLANNING SHEET Process Planning Sheet PPS. No. Methods Eng. ref. Rev. No. Page No. No. FAB 0 0 Total:Client Part Name Rev. NO. Drawing No. Material FacilityProjec Stator frame model 0 SS400 NiltOrder Process Description Process No. MHI/MELCO Date Estimated TimeNo. Reference No.1 Fabrication. 01# 0 24-Feb-10 34 daysOpn. Process IMAGES Target day RemarksNo.1 Documentation Fabrication Drawings 5 REF.OF ACTUAL DRG. Inspection record formats2 Technical standards & work procedures WPS 1 QCL AND QAP 13 MARKING OF SHELL Marking of Centre line of shell by using the 1 divider and punch mark. LONG SEAM MARKING and CIRC. SEAM MARKING4 Cutting & edge preparation Gas cut the of shell as per e-block and t-block 1 dimensions5 CNC CUTTING OF E-SIDE AND T-SIDE PARTS Cutting as per design requirement and grinding 2 of all cut-out of parts after cutting. L&T MHI TURBINE GENERATORS
  42. 42. 6 CNC CUTTING OF FLANGES, MANHOLE, TRUNNION Cutting as per design requirement and grinding of all cut-out of parts after 2 cutting.7 MARKING OF BORE RING AND RIB PLATES Marking of the rib plate as per the design and cut-out the plate in CNC 2 machine then grinding the all parts.8 SET-UP AND ASSEMBLY OF E-BLOCK PARTS all cut-out parts are set-up properly and assemble the structure of E-block 29 WELDING OF E-BLOCK PARTS All parts in joint by the GTAW process as per the welding design10 SET-UP AND ASSEMBLY OF T-BLOCK PARTS 3 All cut-out parts are set-up properly and assemble the structure of T-block11 WELDING OF E-BLOCK PARTS All parts is joint by the GTAW process as per the welding design 112 FULL WELDING OF E-BLOCK WITH SHELL The E-block structure is welded with shell by using GMAW process. 113 FULL WELDING OF T-BLOCK WITH SHELL The T-block structure is welded with shell by using GMAW process. 114 FIT-UP OF OUTER COMPONENTS Fit-Up THE FLANGES, MANHOLE, TRUNNIONS IN THE OUTER SIDE OF 1 SHELL15 WELDING OF COMPONENTS Full welding of components by using GTAW process. 1 L&T MHI TURBINE GENERATORS
  43. 43. 16 MARKING OF FRAME FOOT AND ITS SUPPORTS MARKING OF FRAME FOOT AND ITS SUPPORTS 1 ON THE SHELL17 WELDING OF FRAME FOOT AND ITS SUPPORTS All cut-out parts of frame foot and supports 1 welded by GMAW welding process.18 END PLATE FIT-UP AND WELDING Leveling of shell and end plate with respect of 1 design and full welded19 VISUAL INSPECTION After all welding complete visual check 1 inspection20 DISTORTION REMOVAL Remove all NDT points by grinding and chipping 1 hammer.21 MARKING OF SUPPORTS LEVELLING OF STATOR FRAME Marking and leveling of supports then full welding22 CLEANING AND SURFACE PREPARATION CLEANING AND SURFACE PREPARATION OF ALL 1 WELDED PARTS AND COMPLETE SHELL.23 BLASTING BLASTING USING SMALL PRESSURE APPLIED 124 PAINTING PAINTING OUTER AND INNER SIDE 1 BYMANUALLY.25 DISPATCH 126 PACKING 1 L&T MHI TURBINE GENERATORS
  44. 44. SOME SPECIFIC TERMS USED IN WPSWelding Variables ◦ Essential variables. ◦ Supplementary essential variable. ◦ Non-essential variables.P – Numbers: ◦ To reduce the number of welding procedure qualification required, base metals have been assigned P – Numbers.F – Numbers: ◦ F Numbers are used for filler metal designation and grouping of electrodes & welding rods. ◦ It is based essentially on their usability characteristics.A – Numbers: ◦ A – Numbers are used to identify the weld metal chemical composition of ferrous metals. L&T MHI TURBINE GENERATORS
  45. 45. CONT… Joints • The WPS describe some variable like groove design ,backing etc., Base Metals • It is essential variables for all welding processes. • A change in a base metal thickness beyond the range qualified in table (As per qw-4541) requires the requalification of WPS. Filler Metal • Filler metal should be selected which is compatible to base metal chemical composition (Sec.II_A/B). They must have same/similar chemical composition. • For filler metal chemical composition, we have the refer ASME SEC-II C. L&T MHI TURBINE GENERATORS
  46. 46. CONT… Position • Position is supplementary essential variable. • 1G, 2G, 3G, etc., are different types of welding positions (as per QW-461 Sec IX) Preheat • It can be determine from ASME SEC VIII, Division – 1, Appendix – R. PWHT • ASME SEC – VIII, DIV- I, Per. UCS-56 describes PWHT temperature and time range for specific material with respect to P – Number. L&T MHI TURBINE GENERATORS
  47. 47. CONT… Gases • Three types of gases are described in WPS. o Shielding gas. o Backing gas. • Trailing gas Electrical Characteristics • ELECTRICAL CHARACTERISTICS (QW – 409) • We have to write Current, Polarity, and Voltage as electrical characteristics. Technique • It is determined manually with respect to joint design, material type material thickness etc L&T MHI TURBINE GENERATORS
  48. 48. WPS QW-482 WELDING PROCEDURE QUALIFICATION (WPS) SupportingWPS NO: 1 DATE: 12-3-2012 - PQR No(s) WeldingRevision: RO SMAW ProcessDate: 12-3-2012 Type MANUALJOINTS (QW-402)Groove Design As per Drg.Backing: (Yes/No) YesBacking Material (type) Base metal/Weld metalOther -BASE METALS (QW-403) MATERIAL 1 MATERIAL 2P. No. 1 P. No. 1Group No. 1 Group No. 1Specification/Grade - Specification/Grade -Thickness Range: (mm):5 to 200 mmBase Metal: ss-400 Groove: all Fillet ANYDeposited weld thickness: 200 mm MAX SMAW 6 Fillet ANYOther: 13 mm maximum weld deposition in single pass L&T MHI TURBINE GENERATORS
  49. 49. FILLER METALS(QW-404)Process SMAWF. No. 4A. No. 1 SFASpec No. 5.1AWS No. (class) E 7018 Φ 2.5,Size of filler metals (mm) 3.15, 4,Electrode Flux (class) NAFlux Trade name NAConsumable Insert NAChemical composition NAOther NAPOSITIONS (QW-405)Process(es): SMAWPosition of Groove: ALL F-FlatWelding Progression: uphillPosition of Fillet: ALL H-Horizontal V-VerticalOther None O-OverheadPREHEAT (QW-406)Preheat Temp. (Min):ºC 150 ºCInterpass Temp. (Max):ºC 350 ºCPreheat Maintenance: During Welding L&T MHI TURBINE GENERATORSOther NA
  50. 50. POST WELD HEAT TREATMENT (QW-407) ELECTRICAL CHARACTERISTICS(QW-409)Type of PWHT Current(AC or Dc) DCTEMP. Range: ºC Polarity (EN or EP) EP Amps (Range) 70-155 ASoaking/Holding Time Voltage (Range) 20-30 VRate of Heating Tungsten Type & Size NARate of Cooling Mode of Metal Transfer NA NAOthers: Electrode wire feedGASES (QW-408) Flow % Composition Rate(LPM)Shielding Gas NA NABacking/Purging Gas NA NATrailing Gas NA NAOther NA NATECHNIQUE (QW-410)String/Weave Bead Gas Cup Size NATravel Speed (range) Cont. Tube Work Dist. NAMultiple/Single Electrode Multi/Single Pass (per side) Multi PassOscillation NAClosed to out chamber NACleaning By wire brushMethod of Gouging/Back chip By grindingOther NA L&T MHI TURBINE GENERATORS
  51. 51. Filler Metal Current Max Min Flux Travel SpeedWeld Dia Volt heat Bead Process Trade Range Type & Amp. Range inputLayer Class (mm Name Length Polarity Range (mm/min) ) (KJ/mm) (mm) 2.5 NA DCEP 70-90 20-30 - - - ALL PASS E-7018 3.15 NA DCEP 100-140 20-30 - - - SMAW 4 NA DCEP 155-190 20-30 - - - L&T MHI TURBINE GENERATORS
  52. 52. QW-482 WELDING PROCEDURE SPECIFICATION (WPS) Supporting PQRWPS NO: 3 DATE: 12-3-2012 - No(s)Revision: RO Welding Process GMAWDate: 12/3/2012 Type MachineJOINTS (QW-402)Groove Design As per Drg.Backing: (Yes/No) with and withoutBacking Material (type) Base metal/Weld metalOther -BASE METALS (QW-403) MATERIAL 1 MATERIAL 2P. No. 1 P. No. 1Group No. 1 Group No. 1Specification/Grade SS-400 Specification/Grade SS-400Thickness Range: (mm) 5mm to 200Base Metal: Groove Fillet ANY mm 5 mm to 200Deposited weld thickness GMAW Fillet ANY mmOther: None L&T MHI TURBINE GENERATORS
  53. 53. FILLER METALS(QW-404)Process GMAWF. No. 6A. No. 1Spec No. 5.28AWS No. (class) ER 70S 6Size of filler metals (mm) Φ 1.6Electrode Flux (class) NaFlux Trade name NAConsumable Insert NAChemical composition NAOther NAPOSITIONS (QW-405)Process(es): GMAWPosition of Groove: all F-FlatWelding Progression: NAPosition of Fillet: F,H,V,O H-Horizontal V-VerticalOther None O-OverheadPREHEAT (QW-406)Preheat Temp. (Min):ºC 150*Interpass Temp. (Max):ºC 350*Preheat Maintenance: During weldingOther NA L&T MHI TURBINE GENERATORSPrepared By Reviewed By Approved By
  54. 54. WPS No:POST WELD HEAT TREATMENT (QW-407) ELECTRICAL CHARACTERISTICS(QW-409)Type of PWHT - Current(AC or Dc) DCTEMP. Range: ºC - Polarity (EN or EP) EP - Amps (Range) -Soaking/Holding Time - Voltage (Range) -Rate of Heating - Tungsten Type & Size NARate of Cooling - Mode of Metal Transfer SPRAY - NAOthers: Electrode wire feed -GASES (QW-408) Gas % Composition Flow Rate(LPM)Shielding Gas Ar-Co2 80% to 20% 14 to 24Backing/Purging Gas NA NA NATrailing Gas NA NA NAOther NA NA NATECHNIQUE (QW-410)String/Weave Bead String Gas Cup Size NA 30-200 Cont. Tube WorkTravel Speed (range) 15-22mm mm/min Dist. Multi/SingleMultiple/Single Electrode Single Multi pass Pass (per side)Oscillation NoneClosed to out chamber NoneCleaning With wire brushMethod of Gouging/Back chip -Other - L&T MHI TURBINE GENERATORS
  55. 55. V Filler Metal Current o Min Flux lt Travel Speed MaxWeld R Bead Process Trade Range heat inputLayer Dia a Length Name Type & Amp. (mm/min) Class n (KJ/mm) (mm) Polarity Range g (mm) e 1 8 ER 70S 30-- GMAW 1.6 - DCEP 180-280 - - 6 200mm/min 3 0Prepared by Reviewed by Approved by L&T MHI TURBINE GENERATORS
  56. 56. QW-482 WELDING PROCEDURE SPECIFICATION (WPS)111 DATE: 12-3- Supporting PQRWPS NO: 5 - 2012 No(s)Revision RO Welding Process GTAWDate 12-3-2012 Type ManualJOINTS (QW-402)Groove Design As per Drg.Backing: (Yes/No) NoBacking Material (type) NAOther -BASE METALS (QW-403) MATERIAL 1 MATERIAL 2P. No. 4 P. No. 4Group No. 1,2 Group No. 1,2Specification/Grade - Specification/Grade -Thickness Range: (mm)Base Metal: Groove (5-200mm) Fillet ANYDeposited weld thickness GTAW (5-200mm) Fillet ANYOther: None L&T MHI TURBINE GENERATORS
  57. 57. FILLER METALS(QW-404)Process GTAWF. No. 6A. No. 1Spec No. 5.18AWS No. (class) ER 70S-2Size of filler metals (mm) Φ 1.6, 2.4Electrode Flux (class) NAFlux Trade name NAConsumable Insert NAChemical composition NAOther NAPOSITIONS (QW-405)Process(es): GTAW F-FlatPosition of Groove: ALLWelding Progression: Uphill H-HorizontalPosition of Fillet: ALL V-VerticalOther None O-Overhead L&T MHI TURBINE GENERATORS
  58. 58. PREHEAT (QW-406)Preheat Temp. (Min):ºC -Interpass Temp. (Max):ºC -Preheat Maintenance: -Other -WPS No:POST WELD HEAT TREATMENT (QW-407) ELECTRICAL CHARACTERISTICS(QW-409)Type of PWHT - Current(AC or Dc) DCTEMP. Range: ºC - Polarity (EN or EP) EN - Amps (Range) -Soaking/Holding Time - Voltage (Range) -Rate of Heating - Tungsten Type & Size EWTh-2Rate of Cooling - Mode of Metal Transfer NAOther - Electrode wire feed NAGASES (QW-408)- Gas % Composition Flow Rate(LPM)Shielding Gas Argon 99.995% 8-12Backing/Purging Gas NA NA NATrailing Gas NA NA NAOther NA NA NA L&T MHI TURBINE GENERATORS
  59. 59. TECHNIQUE (QW-410)String/Weave Bead String Gas Cup Size Φ 6.0-10.0mm diaTravel Speed (range) NA Cont. Tube Work Dist. NA Multi/Single Pass (perMultiple/Single Electrode Single Multi Pass side)Oscillation NoneClosed to out chamber NoneCleaning With wire brushMethod of Gouging/Back chip By grindingOther - Filler Metal Current Flux Travel Max Min Trad Speed heatWeld Volt Bead Process Dia e Type & Amp. Range inputLayer Class Range Length (mm) Nam Polarity Range (mm/mi (KJ/mm e n) ) (mm)Root GTAW ER 80S-G 2.4,2.5 NA DCEN 80-120 10-18 - - -Rest GTAW ER 80S-G 2.4,2.5 NA DCEN 110-180 10-18 - - -All SMAW - - NA - - - - - -All SMAW - - NA - - - - - -Prepared by Reviewed by Approved by L&T MHI TURBINE GENERATORS
  60. 60. FUNCTION OF GENERATOR STATOR FRAME L&T MHI TURBINE GENERATORS
  61. 61. PARTS OF GENERATOR STATOR FRAME L&T MHI TURBINE GENERATORS
  62. 62. PARTS OF GENERATOR STATOR FRAME L&T MHI TURBINE GENERATORS
  63. 63. BORE RING • bore ring is mainly use for the supporting the core bolt and balancing the rotor All fabrication process complete after send to assembly shop. Clamping arrangement Outer ring Inner ring L&T MHI TURBINE GENERATORS
  64. 64. After Leveling & centering of bore ring do tack weld elastic plate to bottom Frame plate.Then place new Frame Plate Above it. Do leveling & centering of same frame plate. Do tack weldit with elastic plate below it. Additional temporary support can also be utilize.Then place next `Bore ring + Elastic Plate` and repeat the above process.And so on complete the Centre block assembly fit-up. L&T MHI TURBINE GENERATORS
  65. 65. FRAME FOOT • Frame foot is use for the foundation of the generator. L&T MHI TURBINE GENERATORS
  66. 66. LEAD BOX • Lead box mainly use the Supply the lead outside inside L&T MHI TURBINE GENERATORS
  67. 67. PROCESS Marking frame plate Setting end plate (T side) Mounting ribs of T side block (1st set) Mounting frame plate of T side block Mounting ribs of T side block (2nd set) Mounting 1st frame plate of center block Partial welding ribs of T side block (1st set) Mounting shell plate of T side block Gas cutting hole for lead box adapter Mounting of 1st bore ring L&T MHI TURBINE GENERATORS
  68. 68. CONT…  Mounting of 2nd frame plate of center block  Welding inside frame  Cleaning welding portion, Painting of angle, pipe and flexible beam support  Mounting shell plate of center block  Welding shell plate center block  Mounting lead box adapter  Welding lead box adapter L&T MHI TURBINE GENERATORS
  69. 69. TRUNNION • Lifting the generator L&T MHI TURBINE GENERATORS
  70. 70. COOLER ADAPTER • Cooler adapter is mainly use to cooling the steam. L&T MHI TURBINE GENERATORS
  71. 71. PROCESS Marking frame plate Setting end plate (E side) Mounting ribs of E side block (1st set) Mounting frame plate of E side block Mounting shell plate of E side block Mounting ribs of E side block (1st set) Gas cutting hole for cooler adapter Welding inside frame in flat position Turnover Welding inside frame in flat position L&T MHI TURBINE GENERATORS
  72. 72. L&T MHI TURBINE GENERATORS
  73. 73. L&T MHI TURBINE GENERATORS

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