Bhushan powers and steels thalkuli,regali

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Bhushan powers and steels thalkuli,regali

  1. 1. BHUSHAN POWERS AND STEELSRENGALI,JHARSUGUDAORISSA2012ERECTION AND COMMISSIONING OF 130*1 MW STEAMTURBINE AND GENERATORPREPAIRED :SREENATH M
  2. 2. Objective The idea of this project to achieve the customer requirement in thepower generation field for there steel production and also for thegrid supply According to Siemens this is our 3rd unit of 130 MW with bhushanpowers and steel in jharsuguda, Orissa As per Siemens quality manual of integrated management system,ISO 9001:2000,ISO 10005:2000 and some of the company supportsfor the material and ,machine manuals and for the procedure forspecifications the company are ABB STAL,ABB Alstom , ALSTOMpower and L&T to achieve good quality in Erection andcommissioning safe working environment of turbine and generatorFor that the time of operation.
  3. 3. Typical diagram of a coal-fired thermal power station1. Cooling tower 2. Cooling water pump 3. transmission line (3-phase) 4. Step-up transformer (3-phase) 5. Electricalgenerator (3-phase) 6. Low pressure steam turbine 7. Condensate pump 8. Surface condenser 9. Intermediatepressure steam turbine 10. Steam Control valve 11. High pressure steam turbine 12. Deaerator 13. Feed water heater14. Coal conveyor 15. Coal hopper 16. Coal pulveriser 17. Boiler steam drum 18. Bottom ash hopper 19. Super heater 20.Forced draught (draft) fan 21. Reheated 22. Combustion air intake 23. Economiser 24. Air preheater 25. Precipitator 26.Induced draught (draft) fan 27. Flue gas stackScope of work inbhushan power& steel 1x130MW
  4. 4. ABOUT DEAERATOR SYSTEM Deaerators is a device that is widely used for the removal of oxygen and otherdissolved gases from the feed water to steam-generating boilers. In particular,dissolved oxygen in boiler feed waters will cause serious corrosion damage in steam systemsby attaching to the walls of metal piping and other metallic equipment andforming oxides (rust). Dissolved carbon dioxide combines with water to form carbonicacid that causes further corrosion. Most deaerators are designed to remove oxygen down tolevels of 7 ppb by weight (0.005 cm³/L) or less as well as essentially eliminating carbondioxide.
  5. 5. BHUSAN 130 MWDEAERATOR SPECIFICATIONSDEAREATOREquipment from : ALLIEDS ENERGYSYSTEMSDesigned pressure : 6.12 kg/cm² (g)Designed temperature : 260 ⁰cOperating pressure : 3.82 kg/cm² (g)Capacity : 420.084 TPHHydro tested on : 9.18 kg/cm² (g)Vessel ID & Heigh:2410mm&2853mmSTORAGE WATER TANK Equipment from : ALLIEDS ENERGYSYSTEMSDesigned pressure : 6.12 kg/cm² (g)Designed temperature : 260 ⁰cOperating pressure : 3.82 kg/cm² (g)Capacity : 138.79 mᶟHydro tested on : 9.18 kg/cm² (g)Vessel ID & Heigh:3568mm&4066mmDEAREATORSECTION WITHPLATFORMSTORAGE WATERTANK SECTIONOF DEAREATORWITH PLATFORMTray and nozzlearrangementinside thedeaeratorAt the one endPlaced theTeflon sheet forthe preventionof operationvibration andexpiation
  6. 6. • Condensate line to deaerators inlet• Pegging steam inlet• Overflow & drain for deaerator• BFP suction to deaerators• Initial heating steam• Pump recirculation line• HP3 normal drain• Safety valve• Erection of deaerator & water storage tank completed in :5/7/2012The pipe line which are connected to deaeratorssystem
  7. 7. About surface Condenser A surface condenser is a commonly used term for a water-cooled shell and tubeheat exchanger installed on the exhaust steam from a steam turbine in thermalpower stations. These condensers are heat exchangers which convert steam fromits gaseous to its liquid state at a pressure below atmospheric pressure. Wherecooling water is in short supply, an air-cooled condenser is often used. An air-cooled condenser is however significantly more expensive and cannot achieve aslow a steam turbine exhaust pressure as a water-cooled surface condenser.
  8. 8. SURFACE CONDENSER INBHUSAN 130*1 MWNAME: TWO PASS,DIVIDED WBRECTANGULAR CONDENSERMANUFACTURER : LANSER & TURBO LtdWORKING PRESSURE : In shell/tube :-0.0992 bar/0 barOPERATING TEMP : In shell/tube :-45.66 ⁰C/33⁰C in & 42⁰C outOPERATING FLUID : In shell/tube :-saturated steam/cooling waterDESIGN PRESSURE : In shell/tube :-1&F.V./5 barTEST PRESSURE : In shell/tube :-water filling at site/6.5 barDESIGN TEMPARATURE : In shell/tube:-100 ⁰C/100 ⁰CCORROTION ALLOWANCE :In shell/tube :- 1.6mm/3.2mmSTEAM CAP : 345.384 TPHNORMAL OP WEIGHT : 261 Kg (approx)EMPTY WEIGHT : 155 Kg (approx)MATERIAL COUNSTRACTION :SA516.Gr.70,SA 249.TP.304TUBEARRANGEMENTINSIDE THECONDENSERWATER INLET ANDOUTLET NOZZLEIN CONDENSER &Guiding thecondenser to theTG deckAfter assembly of twosegment condenser &placed on springsupportSpring lockingsystem aftercondenserfloating testHot welllevel ofcondenser
  9. 9. PIPE LINE WHICH ARE CONNECTED TO CONDENSER• CONDANSATE OUTLET• CEP MIN. RECIRCULATION LINE• VACUUM BREAKER CONNECTION• COOLING WATER INLET AND OUTLET LINE• SPARE CONNECTION NOZZLES• HOTWELL DRAIN LINE• LP FLASH TANK DRAIN• PRESSURE AND TEMPARATURE GAUGES• PRESSURE TRANSMITTER CONNECTIONS• Condenser erection and alignment fully completed on :-24/9/2012
  10. 10. ABOUT Feed water heaterA feed water heater is a power plant component used to pre-heat water delivered toa steam generating boiler. Preheating the feed water reduces the irreversibilitys involvedin steam generation and therefore improves the thermodynamic efficiency of the system.This reduces plant operating costs and also helps to avoid thermal shock to the boilermetal when the feed water is introduced back into the steam cycle.There are four processes in the Rankin cycle. These states are identifiedby numbers in the Ts diagram.Process 1-2: The working fluid is pumped from low to high pressure. Asthe fluid is a liquid at this stage the pump requires little input energy.Process 2-3: The high pressure liquid enters a boiler where it is heated atconstant pressure by an external heat source to become a dry saturatedvapour. The input energy required can be easily calculated using mollierdiagram or h-s chart or enthalpy-entropy chart also known as steamtables.Process 3-4: The dry saturated vapour expands through a turbine,generating power. This decreases the temperature and pressure of thevapour, and some condensation may occur. The output in this processcan be easily calculated using the Enthalpy-entropy chart or the steamtables.Process 4-1: The wet vapour then enters a condenser where it iscondensed at a constant temperature to become a saturated liquid.
  11. 11. FEED WATER HEATER INBHUSAN 130*1 MWHPH 3 & 4MANUFACTURED L & TSHELL TUBE UNITDESIGNPRESSURE17/FV &35/FV200 kg/cm² (g)DESIGN TEMP 300 & 265 230 & 265⁰cHYDROTESTED25.5 &52.53OO kg/cm² (g)OPERATINGFLUIDSTEAM FEEDWATEROPERATINGWEIGHT19000 &14600KgWEIGHT FULLOF WATER24600 &18400KgEMPTYWEIGHT16900 &13300KgHIGH PRESSUREHEATER 4 IN BHUSAN130HIGH PRESSUREHEATER 3 IN BHUSAN130
  12. 12. PIPE LINE WHICH CONNECTED TO FEED WATER HEATER 3 & 4• Extraction Bleed 3&4 pipe line to turbine• HPH 3 normal drain to deaerator• HPH 3&4 drain to HP flash tank• Drain from HPH 4 to HPH 3• HPH 4 emergency to flash tank drain line
  13. 13. LOW PRESSURE HEATERSPECIFICATION IN BHUSAN 130• Low pressure heater is to use steam turbineexhaust to heat boiler feed water to reach therequired water temperature in the thermalpower plant. According to water flow, lowpressure heater is installed after condensateexport and before the deaerator. Feed water isthrough low pressure heater before withoutthrough deaerator, so feed water is with highoxygen content and will corrosion the lowpressure heater. Therefore, heat exchange tubeis made by stainless steel tube or thick wallcarbon steel tube.• Our high-pressure heater can be installedaccording to users’ site conditions. There areUpright Vertical, inverted vertical, horizontal,etc.LPH L&T SHELL TUBE UNITDesignpressure3.5/fv 25 kg/cm²(g)Designtemp150 150 ⁰cHydrotested5.25 37.5 kg/cm²(g)Operatingfluidsteam FeedwaterWeight fullof water25200 KgArea: Gross& Effective603.50&582.22Emptyweight13700 KgOperatingweight &area16800 KgInside the heaterBefore causingassembly
  14. 14. PIPE LINE WHICH ARE CONNECTED TO LP HEATERTurbine extraction to LP heaterLPH to deaerator piping for condensationLPH emergency drain and Normal drain to LPflash tank
  15. 15. JACKING OIL SYSTEMS• This pump is generally used only for large turbine-generators , and then only duringthe period when the shaft is rotated by the turning gear.• At the time of turbine start up, the shaft journals are in contact with the whitemetal of the bearings due to the weight of the rotor. The low pressure of thelubricating oil supply when the set is stationary is insufficient to stop the metal tometal contact between journals and bearing shells. In order to prevent the metal tometal contact between journal and bearing shell during start up, which is damagingin the long term, an oil pocket machined into the bottom shell of the journalbearing is supplied with oil under high pressure. This lifts the shafting systemslightly and it floats on a film oil. this is called jacking oil system of turbineJOP motorafteralignmentJacking Oilsystem
  16. 16. FUNCTION OF JACK OIL SYSTEM IN POWERSECTOR A jacking oil pump also called a liftpump is commonly used on rotorshafts of steam driven TurbineGenerators prior to start-up orafter shutdown to provide evencooling of the shaft And eliminate rotor distortioncaused by sags due to weight andbows due to uneven cooling. The jacking oil pump uses highpressure oil supplied at the bearingjournals to initiate an oil film andlift the shaft off its bearings. The rotor can then be put on aturning gear and rotated slowly tocreate even cooling and or roll outany distortions caused by theweight of the shaft while at rest. Line normalizing at:14-01-2013Working & emptyweight1500 & 1000 KgOperating pressure 250 BarsOperatingtemperature45 ⁰cFluid used 150 VG 32Flow 80 LpmTURNNING OIL FILTERWEIGHT 190 & 200 KgDesign pressure &temp210 bar & 90 ⁰cFILTER rate10 micronsENPRO INDUSTRY PVT
  17. 17. OPERATION OF LUBE OIL SYSTEM IN STEAM TURBINE AND GENERATOR It Reduces friction betweenrotating and fixed elements of theturbine and generator such as occur inthe journal bearings and thrustbearings. This reduces wear, reducesheat and improves efficiency. It Removes heat from thebearings. This heat may either begenerated by friction within the bearingor by conduction along the shaft fromthe turbines. In mechanical hydraulic governingsystems, it is used as a hydraulicpressure fluid. In these governingsystems , lubricating oil is used for boththe pilot oil and power oil systems. Line Normalization at : 06-01-2013Empty & workingweight310 & 340 KgFluid used 150 VG 32Flow &Filter rate 1300 Lpm & 20 micronsDesign pressure &temperature8 bar & 100 ⁰cLUBE OIL COOLERWEIGH WORKING & opENPRO INDUSTRY PVT1710 & 1320 KgDesign pressure in shell andtube8 & 5 BarsDesign TEMP in shell andtube100 ⁰cHydro tested on 12 bars7.5
  18. 18. Centrifugal purifier/Oil Purification System/Turbine Wash SkidDuring operation, the lubricating oil becomes contaminated with a variety ofundesirable impurities like• Water which most likely enters the system during shutdown from humidity in the air• Fibres which come from the gasket material used to seal joints in the system.• Sludge which results from the breakdown of the oil into longer chain molecules andresults in a thickening of the oil.• Organic compounds which result from a slow reaction between the oil, oxygen and the.metal piping.• Metal fragments which come from wear products in the bearings and lube oil pumps.• Not only these contaminants destroy the lubricating properties of the oil andaccelerate corrosion, but they can act as a grit within the bearings to cause bearingwear and unevenness. The insoluble impurities can be removed with filters, but thesoluble impurities are only removed by centrifugingCentrifugalmotor andpurificationsystem
  19. 19. CONTROLE OIL SKID/FUEL FORWARDING SKID The Fuel Forwarding Skid along with the Fuel Management Spool provides theturbine with liquid fuel at the appropriate pressure and temperature. Typicallythe Fuel Forwarding Skid includes dual pumps and an electric heater, and theFuel Management Spool includes a pressure control valve and an EPA certifiedflow meter. The benefits of a combined forwarding/preheating skid are toreduced system cost, reduced field installation cost and reduced equipmentfootprint size.FF SInternationalHydro TechnologyGMBHMax AllowablePressure160 barFiltering 12 micronsMax AllowableTemperature10 to 80 ⁰c
  20. 20. FOUNDATION DETAILS FOR GENERATOR AND TURBINE IN BUSHAN 1X130MWAREA OFSOLEPLATEBoltspecificationTightentorque NmACTUALELIVATIONTE Bearing plateat rear sideM 30X4850MM 2700 EL :- 12.290 mTE Bearing plateat front sideM64X3200MM 10300 EL :- 10.713 mGE Bearingplate levelM 36X4850MM 1800 EL :- 11.575 m
  21. 21. GENERATOR AND TURBINE SPECIFICATIONGE.MADE BY:SIEMENSGERMANYFREQUENCY:50HzYEAR OFMANUFACTURE: 2011DIRECTION OFROTATION: CCWNUMBER OFPHASE: 3TYPE OFCOOLING: AIRCOOLINGRANGE OF RATEDVOLTAGE:15000 VRATED CURRENT:6255 ARATED SPEED:3000 rpmPHASESEQUENCE:U1,V1,W1COOLING AIRTEMPERATURE:40⁰CRATED POWER:162500 KVARATED POWER FACTOR:Cos =0.80TOTAL WEIGHT:205 TROTOR WEIGHT:36 TTE.MADE BY:SIEMENSSWEDENSST 900(SIEMENS STEAMTURBINE)SPEED :3000 TO 3600 rpmSTEAMPARAMETER:160bar TO 550⁰CSynchronizationat :08-02-201309:55 PM,15 MW
  22. 22. CEP PUMP AND MOTOR/Vertical installed pumpMFG:-SIEMENSSpecification:-MOTORSpecification:-PUMPVOTAGE 6.6 K v 6.6 K vMAXSPEED1450 rpm 1450 rpmPOWER 300 K w 300 K wCURRENT 33 A 33 AIn a "closed" system, water travels in a loop. Water isheated in the boiler and made into steam. Steam flowsthrough a pipe to a turbine. Steam at lower pressureexhausts into a condenser where heat is removed andthe steam becomes water. The water is removed fromthe "hot well" (the point where the water collects) andmoved into a storage tank which is the supply for thehigh pressure feed pump which puts the water back intothe boiler so it can go round and round. The pump whichremoves the water from the hot well, called condensateat this point, is the pump you are referring to. It is a highvolume, low pressure pump and it may have one ormore stages. It only raises the pressure enough to getthe water out of the condenser and into the systemwhich pipes it to the feed pump.A steam locomotive is an "open" system as it does notcondense the steam back to water, but rather exhauststhe steam to the atmosphere, thus, no condensate pumpneeded. It also means a huge waste of the energy sincethe water is expelled as steam and carries a lot of energywith it. In the closed system, it is possible to use the heatreleased when the steam condenses to preheat the feedwater, recovering some of the energy the open systemloses, which raises the overall efficiency.
  23. 23. Rupture disk on condenser• A rupture disc, also known asa bursting disc or burst diaphragm, isa non-reclosing pressure relief devicethat, in most uses, protectsa pressure vessel, equipment orsystem from over pressurization orpotentiallydamaging vacuum conditions.• if the pressure increases and thesafety valve fails to operate (or cantrelieve enough pressure fast enough),the rupture disc will burst. Rupturediscs are very often used incombination with safety relief valves,isolating the valves from the process,thereby saving on valve maintenanceand creating a leak-tight pressurerelief solution.Rupture discspecificationSize: 22.00Thickness :0.60mmBurst tempand pressureTemp :46⁰CPressure :0.70 Kg/cm²1.Rupture discon thecondenserupper side2.Area/Flangewhere the discto be place3.After placingthe disc in theflange
  24. 24. EJECTOR SYSTEM IN STEAM TURBINEThis the ejector section Forcreating a vacuum pressurein steam turbine andexhaust condenser
  25. 25. • An Ejector, steam ejector, steam injector, educator-jet pump or thermo compressor is atype of pump that uses the Venturing effect of a converging-diverging nozzle to convertthe pressure energy of a motive fluid to velocity energy which creates a low pressurezone that draws in and entrains a suction fluid. After passing through the throat of theinjector, the mixed fluid expands and the velocity is reduced which results inrecompressing the mixed fluids by converting velocity energy back into pressure energy.The motive fluid may be a liquid, steam or any other gas. The entrained suction fluid maybe a gas, a liquid, a slurry, or a dust-laden gas stream.• The adjacent diagram depicts a typical modern ejector. It consists of a motive fluid inletnozzle and a converging-diverging outlet nozzle. Water, air, steam, or any other fluid athigh pressure provides the motive force at the inlet.• The Venturing effect, a particular case of Bernoullis principle, applies to the operation ofthis device. Fluid under high pressure is converted into a high-velocity jet at the throat ofthe convergent-divergent nozzle which creates a low pressure at that point. The lowpressure draws the suction fluid into the convergent-divergent nozzle where it mixes withthe motive fluid.• In essence, the pressure energy of the inlet motive fluid is converted to kinetic energy inthe form of velocity head at the throat of the convergent-divergent nozzle. As the mixedfluid then expands in the divergent diffuser, the kinetic energy is converted back topressure energy at the diffuser outlet in accordance with Bernoullis principle. Steamlocomotives use injectors to pump water into the steam-producing boiler and some ofthe steam is used as the injectors motive fluid. Such "steam injectors" take advantage ofthe latent heat released by the resulting condensation of the motive steam.
  26. 26. Alignment and setups1.Dial gauge(Distance amplifying instrument)Dial indicators are available in many physical sizes and ranges. For most alignment applications thesmaller sized indicators should be used to reduce indicator bar sag. Dial indicators should be chosenthat have a range of 0.100 inch and accurate to 0.001 inch. Indicator readings, and many other typesof readings, are expressed in several units. A reading of 1/1000" is equivalent to 0.001 inch and iscommonly expressed as 1 mil.A common convention used when reading dial indicators is that when the indicator plunger is movedtoward the indicator face the display shows a positive (+) movement of the dial needle by sweepingthe needle clockwise. As the plunger is stroked away from the face a negative (-) reading is displayedby sweeping the needle counterclockwise. Negative movements of the dial needle may be confusing ifthe indicator is not observed carefully throughout the rotation cycle of the machine shafts.
  27. 27. 2.Shaft alignment1. Shaft alignment is the process to align two or more shafts with each other to withina tolerated margin. It is an absolute requirement for machinery.2. When a driver like an electric motor or a turbine is coupled to a pump, a generator,or any other piece of equipment, it is essential that the shafts of the two pieces arealigned. Any misalignment between the two increases the stress on the shafts andwill almost certainly result in excessive wear and premature breakdown of theequipment fore the machinery is put in service. This can be very costly. When theequipment is down, production might be down. Also bearings or mechanical sealsmay be damaged and need to be replaced. A proper shaft alignment or the useof disc couplings can prevent this.3. Tools used to achieve alignment may be mechanical or optical, like the Laser shaftalignment method, or they are gyroscope based. The gyroscope based systems canbe operated very time efficient and can also be even used if the shafts have a largedistance.4. There are two types of misalignment: parallel and angular misalignment. Withparallel misalignment, the centred lines of both shafts are parallel but they areoffset. With angular misalignment, the shafts are at an angle to each other.
  28. 28. 3.Misalignment detailsThe parallel misalignment can be further divided up in horizontal andvertical misalignment Horizontal misalignment is misalignment of the shafts in the horizontal plane and verticalmisalignment is misalignment of the shafts in the vertical plane Parallel horizontal misalignment is where the motor shaft is moved horizontally away from thepump shaft, but both shafts are still in the same horizontal plane and parallel. Parallel vertical misalignment is where the motor shaft is moved vertically away from thepump shaft, but both shafts are still in the same vertical plane and parallel.Similar, angular misalignment can be divided up in horizontal and verticalmisalignment: Angular horizontal misalignment is where the motor shaft is under an angle with the pumpshaft but both shafts are still in the same horizontal plane. Angular vertical misalignment is where the motor shaft is under an angle with the pump shaftbut both shafts are still in the same vertical plane. Errors of alignment can be caused by parallel misalignment, angular misalignment or acombination of the two.
  29. 29. SOME OF THE PHOTOS WE USED TO CHECK THE ALIGNMENT IN130X1 MW BHUSAN STEELFor the alignment of theturbine and generatorfollowing system are weused in the site,1234 567
  30. 30. BLOWING DEVICE ASSEMBLYSteam blowing of MS lines, CRH,HRH,SH,RH,HP & LP bypass pipe lines of turbineis carried out in order to remove welding slag, loose foreign materials, ironpieces, rust etc. from the system, generated during manufacturing,transportation & erection which causes the operation defect of serious damageon turbine & other steam systems.1) Thermal shock2) Removal force of steam3) Cleaning force of steamBlowing Device fixing completed on :19-Oct-201212 3
  31. 31. 456789
  32. 32. 1011121314
  33. 33. 1. First blowing device is fixed to the right of the turbine inSST900 which is guide main steam inlet.2. These is to show that the main steam inlet nozzle this lead thesteam strike to the turbine blades.3. The space washer seat hole, Which help to stopping the weststeam getting inside while blowing undergoes.4. Space washer seat with steel rod and gasket to help fixing inside the lead and also help damage cause on the nozzle afterblowing due to the thermal expansion and contraction.5. Space washer are inserted inside the ESV seat and removedthe guide rode .6. Next is to fixing of lifting tool to the cover and this help to fixthe arrangement in to the seat .7. To the cover place the bimetal ring and graphite ring before liftPlacing.
  34. 34. 8. The cover arrangement taken into the ESV seat after spacewasher assembly fixed.9. After the cover assembly insert split ring into the groove forfixing the cover by using grub screw and tighten to 170NMtorque and maintain the spilt ring gap equally inside the ESVseat.10. After the assembly of cover place horizontally the sleeve fixwith the hexagon socket screw.11. Notice that before fixing the sleeve to cover place steel gasket tothe two ends .13. Lead the assembly inside the ESV seat and tight it.14. At last fix the copper gasket and plug in the device.
  35. 35. ESV ASSEMBLY(Emergency System Vent) PROCEDURE ATSITE• The ESV (Emergency System Vent) valves are normally closed letting theprocess continue normally and prevent-ing the expensive media fromflowing to flare and burn-ing to waste. In an emergency situation, whenpart of the process or the whole process goes down or does not continueto work normally, the production is sent to flare via ESV valves andburned to avoid dangerous materials harming people working at theplant. ESV valves are typi-cally furnished with fail-to-open automaticactuators.• After completing the Blowing process on 15-jan-2012 we start theassembly of ESV on 28-jan-2012.
  36. 36. 1234576 98
  37. 37. 101112131415161718
  38. 38. 1920212223
  39. 39. ESV ASSEMBLY PROCEDURE AT SITE• After the dismantling the whole blowing tools from ESV seat the area fullyand start preparation of ESV400 assembly.• After the assembly of lifting tool in valve seat(Material: STAL 23 37 02)carry the whole arrangement into the ESV.• Carry the valve seat and place parallel to the ESV mouth and allow theseat valve right parallel inside the seat and check the parallelise by usingmaster level.• And maintain the equal gap in between seat and the nozzle, masher thegap by using filler gauge.• Cleaning the steam strainer and preparation for the assembly of liftingequipment .• Place the assembly parallel to the valve seat and move inside and makeparallel by using parallel pin check the gap using filler gauge.• Assembly the Gland; Ring gasket, Support ring carefully before theassembly of split ring to fix the steam strainer in to the hole.
  40. 40. • After the assembly of (4 nos)split ring maintain the gap between the ringsequal and lock allow Lock ring; Locking ring to fixing the split ring. After theassembly of lock ring tighten the hexagonal socket head screw in 80 NM whichis the required torque.• Stand; Support ESV will assembled with the steam strainer and bolt to therequired torque of 200 NM and tighten the Stand with turbine ESV section at194 NM torque• After the tighten the bolt assemble the gland plate tight with Spring unit; Liveload Assembly. Maintain the gap of 1mm in between gland plate and the springunit and torque tighten at 45 NM .• Servo motor; ESV Servo Motor assemble after the link up with stand stud tostrainer stud,and tight the servo motor with stand at the torque of 100 NM• Connect all COP pipe line to the seromotor solinoidal valves .And operatethrought DCS.
  41. 41. TURNING GEAR & QUILL SHAFT ASSEMBLY• A Jacking gear (also known as a Turning gear) is a device placed on themain engine shaft of a marine vessel. Its main purpose is to rotate theshaft and associated machinery.• The jacking gear motor is designed to rotate the shaft at approximately1/10rpm. Most jacking gear motors are rated at 5hp. The jacking gearmotor assembly applies power and torque to the reduction gear by aflexible coupling or clutch that can freely engage and disengage to thehigh-pressure pinion (driving gear). Engaging is accomplished by means ofa simple lever. Some newer propulsion arrangements utilize an automaticcontrol system located in the engine room. Jacking gears often feature alock to prevent the shaft from turning during current or tide changes orwhen being towed.• A quill shaft, by definition, is a solid shaft which is strategically designedand carefully machined so that it carries the same torque that a largershaft would handle by operating at higher stress levels. In carrying torquethe quill shaft acts like a torsion spring, twisting along its length.
  42. 42. TURNING GEAR & QUILL SHAFT ASSEMBLYPROCEDURE AT SITE12 345678
  43. 43. 9101112131415161718
  44. 44. TURNING GEAR & QUILL SHAFT ASSEMBLY PROCEDURE AT SITE1. Before starting the assembly of Quill shaft to clean all the matchingflange, screw holes and etc using oil or some kind of rust preventer andclean the tactile which is applied from the factories.2. After the cleaning of All assembly parts. Assembly the bottom cover ofQuill shaft on the front side of the turbine, Which removed whilealignment process undergone.3. At the same time remove the side plate from the bottom cover which isused for the fixing of the side glass.4. Completely tighten the bottom cover and check the gape in between thematching face using filler gauge.5. After the completion of above step, start the assembly of Quill shaft, liftshaft using Crain and place the shaft in between the T and G rotor front.6. Match the Face and coupled with two end using Cylindrical pin formaintain the magnetic center.7. Use the M20x100 screw for pull the rotor and tighten and match the faceof coupling. And torque tighten this at 333NM
  45. 45. 9. Lock the pin with shaft by using Set screw of 8x20 mm.10. After the completion of Quill shaft assembly remove the turning geartemporary covering plate used for transport.11. Carry the turning gear using hand and place inside that hole, note that at thetime of assembly the gear system is at the disengage mode .12 Tighten the screw with required torque.13 After that according to the nozzles pipe line to fix with the solenoid, Checkweather it get engage or disengage properly with the teeth
  46. 46. CONTROL VALVE ASSEMBLY PROCEDURE AT SITE1 234 567
  47. 47. 89 10 1112 13 1415 16 17 18 19 20
  48. 48. Final DCS Reading After Commissioning in thesteam system
  49. 49. Final DCS Reading After Commissioning of theTurbine and Generator end
  50. 50. Final DCS Reading After Commissioning Of Control oilsystem
  51. 51. Final DCS Reading After Commissioning Of Lubeoil system
  52. 52. Final DCS Reading After Commissioning Of GlandSteam System
  53. 53. THANKS YOUAnd Thanks to all our team member and for there hard work for thesuccessful completion in Erection and commission of steam turbine atBhushan steels and power( 130x1 MW )

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