Bhushan powers and steels thalkuli,regali

BHUSHAN POWERS AND STEELS RENGALI,JHARSUGUDA

ORISSA2012

ERECTION AND COMMISSIONING OF 130*1 MW STEAM TURBINE AND GENERATOR

PREPAIRED : SREENATH M

Objective

The idea of this project to achieve the customer requirement in the power generation field for there steel production and also for the grid supply

According to Siemens this is our 3rd unit of 130 MW with bhushan powers 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 supports for the material and ,machine manuals and for the procedure for specifications the company are ABB STAL,ABB Alstom , ALSTOM power and L&T to achieve good quality in Erection and commissioning safe working environment of turbine and generator For that the time of operation.

Typical diagram of a coal-fired thermal power station

1. Cooling tower 2. Cooling water pump 3. transmission line (3-phase) 4. Step-up transformer (3-phase) 5. Electrical generator (3-phase) 6. Low pressure steam turbine 7. Condensate pump 8. Surface condenser 9. Intermediate pressure steam turbine 10. Steam Control valve 11. High pressure steam turbine 12. Deaerator 13. Feed water heater 14. 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 stack

Scope of work in bhushan power & steel 1x130MW

ABOUT DEAERATOR SYSTEM

Deaerators is a device that is widely used for the removal of oxygen and other dissolved gases from the feed water to steam-generating boilers. In particular, dissolved oxygen in boiler feed waters will cause serious corrosion damage in steam systems by attaching to the walls of metal piping and other metallic equipment and forming oxides (rust). Dissolved carbon dioxide combines with water to form carbonic acid that causes further corrosion. Most deaerators are designed to remove oxygen down to levels of 7 ppb by weight (0.005 cm³/L) or less as well as essentially eliminating carbon dioxide.

BHUSAN 130 MW DEAERATOR SPECIFICATIONS

DEAREATOREquipment from : ALLIEDS ENERGY SYSTEMS

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&2853mm

STORAGE WATER TANK Equipment from : ALLIEDS ENERGY SYSTEMS

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&4066mm

DEAREATOR SECTION WITH

PLATFORM

STORAGE WATER TANK SECTION OF DEAREATOR

WITH PLATFORM

Tray and nozzle arrangement

inside the deaerator

At the one end Placed the

Teflon sheet for the prevention

of operation vibration and

expiation

• 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 :5/7/2012

The pipe line which are connected to deaerators system

About surface Condenser

A surface condenser is a commonly used term for a water-cooled shell and tube heat exchanger installed on the exhaust steam from a steam turbine in thermal power stations. These condensers are heat exchangers which convert steam from its gaseous to its liquid state at a pressure below atmospheric pressure. Where cooling water is in short supply, an air-cooled condenser is often used. An air-cooled condenser is however significantly more expensive and cannot achieve as low a steam turbine exhaust pressure as a water-cooled surface condenser.

SURFACE CONDENSER IN BHUSAN 130*1 MW

NAME: TWO PASS,DIVIDED WB RECTANGULAR CONDENSERMANUFACTURER : LANSER & TURBO LtdWORKING PRESSURE : In shell/tube :- 0.0992 bar/0 barOPERATING TEMP : In shell/tube :- 45.66 ⁰C/33⁰C in & 42⁰C outOPERATING FLUID : In shell/tube :- saturated steam/cooling waterDESIGN PRESSURE : In shell/tube :- 1&F.V./5 barTEST PRESSURE : In shell/tube :- water filling at site/6.5 barDESIGN TEMPARATURE : In shell/tube:- 100 ⁰C/100 ⁰C CORROTION ALLOWANCE : In shell/tube :- 1.6mm/3.2mmSTEAM CAP : 345.384 TPHNORMAL OP WEIGHT : 261 Kg (approx)EMPTY WEIGHT : 155 Kg (approx)MATERIAL COUNSTRACTION : SA516.Gr.70,SA 249.TP.304

TUBE ARRANGEMENT

INSIDE THE CONDENSER

WATER INLET AND OUTLET NOZZLE

IN CONDENSER & Guiding the

condenser to the TG deck

After assembly of two segment condenser &

placed on spring support

Spring locking system after condenser

floating test

Hot well level of

condenser

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

ABOUT Feed water heater

A feed water heater is a power plant component used to pre-heat water delivered to a steam generating boiler. Preheating the feed water reduces the irreversibility's involved in 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 boiler metal when the feed water is introduced back into the steam cycle.

There are four processes in the Rankin cycle. These states are identified by numbers in the Ts diagram.Process 1-2: The working fluid is pumped from low to high pressure. As the 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 at constant pressure by an external heat source to become a dry saturated vapour. The input energy required can be easily calculated using mollier diagram or h-s chart or enthalpy-entropy chart also known as steam tables.Process 3-4: The dry saturated vapour expands through a turbine, generating power. This decreases the temperature and pressure of the vapour, and some condensation may occur. The output in this process can be easily calculated using the Enthalpy-entropy chart or the steam tables.Process 4-1: The wet vapour then enters a condenser where it is condensed at a constant temperature to become a saturated liquid.

FEED WATER HEATER IN BHUSAN 130*1 MW

HPH 3 & 4MANUFACTURED L & T

SHELL TUBE UNIT

DESIGN PRESSURE

17/FV & 35/FV

200 kg/cm² (g)

DESIGN TEMP 300 & 265 230 & 265 ⁰c

HYDROTESTED

25.5 & 52.5

3OO kg/cm² (g)

OPERATING FLUID

STEAM FEED WATER

OPERATING WEIGHT

19000 & 14600 Kg

WEIGHT FULL OF WATER

24600 & 18400 Kg

EMPTY WEIGHT

16900 & 13300 Kg

HIGH PRESSURE HEATER 4 IN BHUSAN

130

HIGH PRESSURE HEATER 3 IN BHUSAN

130

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

LOW PRESSURE HEATER SPECIFICATION IN BHUSAN 130

• Low pressure heater is to use steam turbine exhaust to heat boiler feed water to reach the required water temperature in the thermal power plant. According to water flow, low pressure heater is installed after condensate export and before the deaerator. Feed water is through low pressure heater before without through deaerator, so feed water is with high oxygen content and will corrosion the low pressure heater. Therefore, heat exchange tube is made by stainless steel tube or thick wall carbon steel tube.

• Our high-pressure heater can be installed according to users’ site conditions. There are Upright Vertical, inverted vertical, horizontal, etc.

LPH L&T SHELL TUBE UNIT

Design pressure

3.5/fv 25 kg/cm² (g)

Design temp

150 150 ⁰c

Hydro tested

5.25 37.5 kg/cm² (g)

Operating fluid

steam Feed water

Weight full of water

25200 Kg

Area: Gross & Effective

603.50& 582.22

Empty weight

13700 Kg

Operating weight & area

16800 Kg Inside the heater Before causing

assembly

PIPE LINE WHICH ARE CONNECTED TO LP HEATER

Turbine extraction to LP heater LPH to deaerator piping for condensationLPH emergency drain and Normal drain to LP

flash tank

JACKING OIL SYSTEMS

• This pump is generally used only for large turbine-generators , and then only during the 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 white metal of the bearings due to the weight of the rotor. The low pressure of the lubricating oil supply when the set is stationary is insufficient to stop the metal to metal contact between journals and bearing shells. In order to prevent the metal to metal contact between journal and bearing shell during start up, which is damaging in the long term, an oil pocket machined into the bottom shell of the journal bearing is supplied with oil under high pressure. This lifts the shafting system slightly and it floats on a film oil. this is called jacking oil system of turbine

JOP motor after

alignment

Jacking Oil system

FUNCTION OF JACK OIL SYSTEM IN POWER SECTOR

A jacking oil pump also called a lift pump is commonly used on rotor shafts of steam driven Turbine Generators prior to start-up or after shutdown to provide even cooling of the shaft

And eliminate rotor distortion caused by sags due to weight and bows due to uneven cooling.

The jacking oil pump uses high pressure oil supplied at the bearing journals to initiate an oil film and lift the shaft off its bearings.

The rotor can then be put on a turning gear and rotated slowly to create even cooling and or roll out any distortions caused by the weight of the shaft while at rest.

Line normalizing at:14-01-2013

Working & empty weight 1500 & 1000 Kg

Operating pressure 250 Bars

Operating temperature 45 ⁰c

Fluid used 150 VG 32

Flow 80 Lpm

TURNNING OIL FILTERWEIGHT 190 & 200 Kg

Design pressure & temp 210 bar & 90 ⁰c

FILTER rate10 micronsENPRO INDUSTRY PVT

OPERATION OF LUBE OIL SYSTEM IN STEAM TURBINE AND GENERATOR

It Reduces friction between rotating and fixed elements of the turbine and generator such as occur in the journal bearings and thrust bearings. This reduces wear, reduces heat and improves efficiency.

It Removes heat from the bearings. This heat may either be generated by friction within the bearing or by conduction along the shaft from the turbines.

In mechanical hydraulic governing

systems, it is used as a hydraulic pressure fluid. In these governing systems , lubricating oil is used for both the pilot oil and power oil systems.

Line Normalization at : 06-01-2013

Empty & working weight

310 & 340 Kg

Fluid used 150 VG 32Flow &Filter rate 1300 Lpm & 20 microns

Design pressure & temperature

8 bar & 100 ⁰c

LUBE OIL COOLERWEIGH WORKING & op

ENPRO INDUSTRY PVT 1710 & 1320 Kg

Design pressure in shell and tube

8 & 5 Bars

Design TEMP in shell and tube

100 ⁰c

Hydro tested on 12 bars7.5

Centrifugal purifier /Oil Pur ification System/Tur bine Wash Skid

During operation, the lubricating oil becomes contaminated with a variety of undesirable 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 and

results 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 and accelerate corrosion, but they can act as a grit within the bearings to cause bearing wear and unevenness. The insoluble impurities can be removed with filters, but the soluble impurities are only removed by centrifuging

Centrifugal motor and purification

system

CONTROLE OIL SKID/FUEL FORWARDING SKID

The Fuel Forwarding Skid along with the Fuel Management Spool provides the

turbine with liquid fuel at the appropriate pressure and temperature. Typically the Fuel Forwarding Skid includes dual pumps and an electric heater, and the Fuel Management Spool includes a pressure control valve and an EPA certified flow meter. The benefits of a combined forwarding/preheating skid are to reduced system cost, reduced field installation cost and reduced equipment footprint size.

FF SInternational Hydro Technology GMBH

Max Allowable Pressure

160 bar

Filtering 12 microns

Max AllowableTemperature

10 to 80 ⁰c

FOUNDATION DETAILS FOR GENERATOR AND TURBINE IN BUSHAN 1X130MW

AREA OF SOLEPLATE

Bolt specification

Tighten torque Nm

ACTUAL ELIVATION

TE Bearing plate at rear side

M 30X4850MM 2700 EL :- 12.290 m

TE Bearing plate at front side

M64X3200MM 10300 EL :- 10.713 m

GE Bearing plate level

M 36X4850MM 1800 EL :- 11.575 m

GENERATOR AND TURBINE SPECIFICATION

GE.MADE BY:SIEMENS GERMANY

FREQUENCY:50Hz

YEAR OF MANUFACTURE: 2011

DIRECTION OF ROTATION: CCW

NUMBER OF PHASE: 3

TYPE OF COOLING: AIR COOLING

RANGE OF RATED VOLTAGE:15000 V

RATED CURRENT: 6255 A

RATED SPEED:3000 rpm

PHASE SEQUENCE:U1,V1,W1

COOLING AIR TEMPERATURE:40⁰C

RATED POWER:162500 KVA

RATED POWER FACTOR:Cos=0.80

TOTAL WEIGHT: 205 T

ROTOR WEIGHT: 36 T

TE.MADE BY:SIEMENSSWEDEN

SST 900(SIEMENS STEAM TURBINE)

SPEED :3000 TO 3600 rpm

STEAM PARAMETER:160 bar TO 550⁰C

Synchronization at :08-02-201309:55 PM,15 MW

CEP PUMP AND MOTOR/Vertical installed pump

MFG:-SIEMENS

Specification:-MOTOR

Specification:-PUMP

VOTAGE 6.6 K v 6.6 K v

MAX SPEED

1450 rpm 1450 rpm

POWER 300 K w 300 K w

CURRENT 33 A 33 A

In a "closed" system, water travels in a loop. Water is heated in the boiler and made into steam. Steam flows through a pipe to a turbine. Steam at lower pressure exhausts into a condenser where heat is removed and the steam becomes water. The water is removed from the "hot well" (the point where the water collects) and moved into a storage tank which is the supply for the high pressure feed pump which puts the water back into the boiler so it can go round and round. The pump which removes the water from the hot well, called condensate at this point, is the pump you are referring to. It is a high volume, low pressure pump and it may have one or more stages. It only raises the pressure enough to get the water out of the condenser and into the system which pipes it to the feed pump.A steam locomotive is an "open" system as it does not condense the steam back to water, but rather exhausts the steam to the atmosphere, thus, no condensate pump needed. It also means a huge waste of the energy since the water is expelled as steam and carries a lot of energy with it. In the closed system, it is possible to use the heat released when the steam condenses to preheat the feed water, recovering some of the energy the open system loses, which raises the overall efficiency.

Rupture disk on condenser

• A rupture disc, also known as a bursting disc or burst diaphragm, is a non-reclosing pressure relief device that, in most uses, protects a pressure vessel, equipment or system from over pressurization or potentially damaging vacuum conditions.

• if the pressure increases and the safety valve fails to operate (or can't relieve enough pressure fast enough), the rupture disc will burst. Rupture discs are very often used in combination with safety relief valves, isolating the valves from the process, thereby saving on valve maintenance and creating a leak-tight pressure relief solution.

Rupture discspecification

Size : 22.00

Thickness :0.60mm

Burst temp and pressure

Temp :46⁰C

Pressure :0.70 Kg/cm²

1.Rupture disc on the condenser upper side

2.Area/Flange where the disc to be place

3.After placing the disc in the flange

EJECTOR SYSTEM IN STEAM TURBINE

This the ejector section For creating a vacuum pressure

in steam turbine and exhaust condenser

• An Ejector, steam ejector, steam injector, educator-jet pump or thermo compressor is a type of pump that uses the Venturing effect of a converging-diverging nozzle to convert the pressure energy of a motive fluid to velocity energy which creates a low pressure zone that draws in and entrains a suction fluid. After passing through the throat of the injector, the mixed fluid expands and the velocity is reduced which results in recompressing 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 may be 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 inlet nozzle and a converging-diverging outlet nozzle. Water, air, steam, or any other fluid at high pressure provides the motive force at the inlet.

• The Venturing effect, a particular case of Bernoulli's principle, applies to the operation of this device. Fluid under high pressure is converted into a high-velocity jet at the throat of the convergent-divergent nozzle which creates a low pressure at that point. The low pressure draws the suction fluid into the convergent-divergent nozzle where it mixes with the motive fluid.

• In essence, the pressure energy of the inlet motive fluid is converted to kinetic energy in the form of velocity head at the throat of the convergent-divergent nozzle. As the mixed fluid then expands in the divergent diffuser, the kinetic energy is converted back to pressure energy at the diffuser outlet in accordance with Bernoulli's principle. Steam locomotives use injectors to pump water into the steam-producing boiler and some of the steam is used as the injector's motive fluid. Such "steam injectors" take advantage of the latent heat released by the resulting condensation of the motive steam.

Alignment and setups

1.Dial gauge(Distance amplifying instrument) Dial indicators are available in many physical sizes and ranges. For most alignment applications the smaller sized indicators should be used to reduce indicator bar sag. Dial indicators should be chosen that have a range of 0.100 inch and accurate to 0.001 inch. Indicator readings, and many other types of readings, are expressed in several units. A reading of 1/1000" is equivalent to 0.001 inch and is commonly expressed as 1 mil.A common convention used when reading dial indicators is that when the indicator plunger is moved toward the indicator face the display shows a positive (+) movement of the dial needle by sweeping the needle clockwise. As the plunger is stroked away from the face a negative (-) reading is displayed by sweeping the needle counterclockwise. Negative movements of the dial needle may be confusing if the indicator is not observed carefully throughout the rotation cycle of the machine shafts.

2.Shaft alignment1. Shaft alignment is the process to align two or more shafts with each other to within

a 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 are aligned. Any misalignment between the two increases the stress on the shafts and will almost certainly result in excessive wear and premature breakdown of the equipment fore the machinery is put in service. This can be very costly. When the equipment is down, production might be down. Also bearings or mechanical seals may be damaged and need to be replaced. A proper shaft alignment or the use of disc couplings can prevent this.

3. Tools used to achieve alignment may be mechanical or optical, like the Laser shaft alignment method, or they are gyroscope based. The gyroscope based systems can be operated very time efficient and can also be even used if the shafts have a large distance.

4. There are two types of misalignment: parallel and angular misalignment. With parallel misalignment, the centred lines of both shafts are parallel but they are offset. With angular misalignment, the shafts are at an angle to each other.

3.Misalignment details

The parallel misalignment can be further divided up in horizontal andvertical misalignment Horizontal misalignment is misalignment of the shafts in the horizontal plane and vertical

misalignment is misalignment of the shafts in the vertical plane Parallel horizontal misalignment is where the motor shaft is moved horizontally away from the

pump 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 the

pump 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 pump

shaft 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 shaft

but both shafts are still in the same vertical plane. Errors of alignment can be caused by parallel misalignment, angular misalignment or a

combination of the two.

SOME OF THE PHOTOS WE USED TO CHECK THE ALIGNMENT IN 130X1 MW BHUSAN STEEL

For the alignment of the turbine and generator

following system are we used in the site,

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BLOWING DEVICE ASSEMBLY

Steam blowing of MS lines, CRH,HRH,SH,RH,HP & LP bypass pipe lines of turbine is carried out in order to remove welding slag, loose foreign materials, iron pieces, rust etc. from the system, generated during manufacturing, transportation & erection which causes the operation defect of serious damage on turbine & other steam systems.1) Thermal shock2) Removal force of steam3) Cleaning force of steam

Blowing Device fixing completed on :19-Oct-2012

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1. First blowing device is fixed to the right of the turbine in SST900 which is guide main steam inlet.

2. These is to show that the main steam inlet nozzle this lead the steam strike to the turbine blades.

3. The space washer seat hole, Which help to stopping the west steam getting inside while blowing undergoes.

4. Space washer seat with steel rod and gasket to help fixing in side the lead and also help damage cause on the nozzle after blowing due to the thermal expansion and contraction.

5. Space washer are inserted inside the ESV seat and removed the guide rode .

6. Next is to fixing of lifting tool to the cover and this help to fix the arrangement in to the seat .

7. To the cover place the bimetal ring and graphite ring before lift Placing.

8. The cover arrangement taken into the ESV seat after space washer assembly fixed.

9. After the cover assembly insert split ring into the groove for fixing the cover by using grub screw and tighten to 170NM torque and maintain the spilt ring gap equally inside the ESV seat.

10. After the assembly of cover place horizontally the sleeve fix with the hexagon socket screw.

11. Notice that before fixing the sleeve to cover place steel gasket to the 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.

ESV ASSEMBLY(Emergency System Vent) PROCEDURE AT SITE

• The ESV (Emergency System Vent) valves are normally closed letting the process continue normally and preventi ng the expensive media from flowing to flare and burn ing to waste. In an emergency situation, when part of the process or the whole process goes down or does not continue to work normally, the production is sent to flare via ESV valves and burned to avoid dangerous materials harming people working at the plant. ESV valves are typi cally furnished with fail-to-open automatic actuators.

• After completing the Blowing process on 15-jan-2012 we start the assembly of ESV on 28-jan-2012.

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ESV ASSEMBLY PROCEDURE AT SITE

• After the dismantling the whole blowing tools from ESV seat the area fully and 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 the seat valve right parallel inside the seat and check the parallelise by using master level.

• And maintain the equal gap in between seat and the nozzle, masher the gap by using filler gauge.

• Cleaning the steam strainer and preparation for the assembly of lifting equipment .

• Place the assembly parallel to the valve seat and move inside and make parallel by using parallel pin check the gap using filler gauge.

• Assembly the Gland; Ring gasket, Support ring carefully before the assembly of split ring to fix the steam strainer in to the hole.

• After the assembly of (4 no's)split ring maintain the gap between the rings equal and lock allow Lock ring; Locking ring to fixing the split ring. After the assembly of lock ring tighten the hexagonal socket head screw in 80 NM which is the required torque.

• Stand; Support ESV will assembled with the steam strainer and bolt to the required torque of 200 NM and tighten the Stand with turbine ESV section at 194 NM torque

• After the tighten the bolt assemble the gland plate tight with Spring unit; Live load Assembly. Maintain the gap of 1mm in between gland plate and the spring unit and torque tighten at 45 NM .

• Servo motor; ESV Servo Motor assemble after the link up with stand stud to strainer 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 operate throught DCS.

TURNING GEAR & QUILL SHAFT ASSEMBLY

• A Jacking gear (also known as a Turning gear) is a device placed on the main engine shaft of a marine vessel. Its main purpose is to rotate the shaft and associated machinery.

• The jacking gear motor is designed to rotate the shaft at approximately 1/10rpm. Most jacking gear motors are rated at 5hp. The jacking gear motor assembly applies power and torque to the reduction gear by a flexible coupling or clutch that can freely engage and disengage to the high-pressure pinion (driving gear). Engaging is accomplished by means of a simple lever. Some newer propulsion arrangements utilize an automatic control system located in the engine room. Jacking gears often feature a lock to prevent the shaft from turning during current or tide changes or when being towed.

• A quill shaft, by definition, is a solid shaft which is strategically designed and carefully machined so that it carries the same torque that a larger shaft would handle by operating at higher stress levels. In carrying torque the quill shaft acts like a torsion spring, twisting along its length.

TURNING GEAR & QUILL SHAFT ASSEMBLY PROCEDURE AT SITE

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TURNING GEAR & QUILL SHAFT ASSEMBLY PROCEDURE AT SITE

1. Before starting the assembly of Quill shaft to clean all the matching flange, screw holes and etc using oil or some kind of rust preventer and clean the tactile which is applied from the factories.

2. After the cleaning of All assembly parts. Assembly the bottom cover of Quill shaft on the front side of the turbine, Which removed while alignment process undergone.

3. At the same time remove the side plate from the bottom cover which is used for the fixing of the side glass.

4. Completely tighten the bottom cover and check the gape in between the matching face using filler gauge.

5. After the completion of above step, start the assembly of Quill shaft, lift shaft 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 for maintain the magnetic center.

7. Use the M20x100 screw for pull the rotor and tighten and match the face of coupling. And torque tighten this at 333NM

9. Lock the pin with shaft by using Set screw of 8x20 mm.10. After the completion of Quill shaft assembly remove the turning gear

temporary covering plate used for transport.11. Carry the turning gear using hand and place inside that hole, note that at the

time 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, Check

weather it get engage or disengage properly with the teeth

CONTROL VALVE ASSEMBLY PROCEDURE AT SITE

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Final DCS Reading After Commissioning in the steam system

Final DCS Reading After Commissioning of the Turbine and Generator end

Final DCS Reading After Commissioning Of Control oil system

Final DCS Reading After Commissioning Of Lube oil system

Final DCS Reading After Commissioning Of Gland Steam System

THANKS YOUAnd Thanks to all our team member and for there hard work for the

successful completion in Erection and commission of steam turbine at Bhushan steels and power( 130x1 MW )