660mw Turbine (Dongfang)

I. Overview

1. Scope of application

This instruction manual is only applicable to the installation and maintenance work of D660MW turbine.

This instruction manual only provides the installation items and requirements of the turbine proper and its

related parts and components and does not provide specific description of the conventional procedures in

the installation (e.g. cleaning, cutting, fastening blot, lock washer etc).

This instruction manual is a general purpose instructive technical document and is not for a particular project or tool.

Before installation, the installation personnel shall carefully read and get familiar with the content of this

instruction manual.

2. Direction for use of this instruction manual

This instruction manual contains the following two aspects:

(1) Turbine installation flow chart

This part provides the turbine installation work process to be performed on site. It is recommended that this flow chart be used as the instruction for the turbine installation schedule on site.

(2) Description of turbine installation procedure on site

This instruction manual provides the site turbine installation sequence and its relation as well as necessary

precautions in the installation and the site turbine installation shall be carried out according to this

instruction manual.

This instruction manual lists in detail all steps and descriptions of turbine installation on site.

This instruction manual also provides some site turbine installation data and related instructive description for site installation.

3. Requirements for inspection tools

All measuring tools mentioned in this instruction manual and to be used in site turbine installation shall be

confirmed and calibrated.

4. Basic requirement for record

(1) The site turbine installation record shall be filled in according to the requirements of this instruction manual.

2) Content of installation record shall meet the requirements of the certificate.

(3) Installation record data shall be in the allowable range of this instruction manual (conventional

requirements for site turbine installation) conform to the requirements of the "Manual of Turbine for Site

Engineer" (Dongfang Turbine Works Standard).

(4) The over-limit dimension must be rechecked and specially noted in the record and submitted to the

Dongfang Turbine Works Quality Assurance Department for confirmation.

(5) All dimension records must be approved by the inspector (quality inspector or Dongfang Turbine

Works supervision engineer) for approval.

5. Conventional requirements for turbine installation inspection on site

(1) Site welding is prohibited

Unless otherwise required in the drawings or this manual, site welding (including spot welding) of

turbine parts and components is strictly forbidden.

(2) Storage of loose parts

As loose parts have been removed of the manufacturer's antirust protection during turbine installation on

site, the loose parts in this case must undergo temporarily rust-proofing treatment and be stored indoors.

(3) Remove parts antirust protection

The antirust protection prior to delivery by the manufacturer is divided into temporary antirust protection

and permanent antirust protection, and the manufacturer's temporary antirust protection should be

removed when the turbine is installed on site.

(4) Requirement for package removal

It is not allowed to disassemble the parts (e.g. rotor) already calked and locked in the manufacturer's

factory as well as those adjusted independent parts (e.g. governor, protection equipment etc.)

(5) Protection in turbine installation on site

When the turbine is installed on site, the installed parts should be covered with fire plate for protection in

the non-working hours to avoid dust contamination and foreign matter drop-in. At the same time, rubber

plate (or other similar materials) should be inserted into the horizontal joint to avoid serious scratch

(excessive scratch will cause the unit to leak in operation).

(6) Rust preventive measures for turbine installation on site

Since the manufacturer's antirust protection for all parts has been removed when the turbine is installed

on site and some parts (e.g. high and medium outer casing and low pressure outer casing upper half) are

not used before completion of final unit installation, these parts should undergo temporary antirust

treatment on site.

(7) Precautions for site turbine installation and lifting

All parts are provided with lifting lugs or screws and all sizes of lifting screw holes are provided with

corresponding sizes of lifting screws. When lifting the parts, it is necessary to choose matching lifting

screws and completely screw in the lifting screws.

When the lifting screw can not be completely threaded into the screw hole, the lifting screw hole should

be re-tapped.

The lifting screws, after tightened, should not be knocked, or deformation will be caused. Lifting of some

parts (e.g. rotor) need special tooling.

Before lifting, all parts should be adjusted for center of gravity and always kept balance during lifting.

Example of installation instruction manual

No. Working content

1. Preparation for low pressure

cylinder installation:

Ensure the height between the top

surface of bed frame and condenser.

Check the condenser throat flange

planeness and elevation from the

flange surface to the top surface of the

bed frame.

2. Contact check between the lower

half of the low pressure cylinder and

the bed frame:

After the lower half of the low

pressure cylinder is installed, check its

contact with the bed frame and ensure

their even contact.

Also check .........

II. Site Turbine Installation Flow Chart

• Template check

• Turbine foundation dimension record •Record ofburial pipe position in the embedded parts! and perpendicularity Record of bed frame concrete pillar

gasket and its

• Record of bed frame contact and clearance

• Check record of vertical joint face

casing of low pressure cylinders A

• Install steam piping

• Bearing pedestal alignment record

• Record of bearing assembling and contact between bearing

spherical surface and bearing pedestal •Dye penetrant inspection record of low level oil pipe weld

• Bearing span record

• Low level oil pipe clearance record

• Positioning of high and medium

• Positioning of high and medium

• Pre-alignment

regulating valvei installation record • Combined reheat valve installation record

Casing alignment

Installation of embedded parts

Placement of operating floor

concrete

Correction of reference point levelness I ----------------

Adjustment of bed frame contact with bed frame • Record of bed frame clearance

Installation of low pressure casing

Installation of bearing housing

Installation of high and medium cylinders

levelness,

clearance of low pressure cylinder • Install outer casing and inner

and B

outer casings

inner casings

• Parallelism check record • High pressure main steam

• asistall the upper half casing (inner

• Tighten the horizontal joint bolt

alignment)

• nderadjustment of backing plate

• Lug sag check record • Condenser throat welding record • High pressure cylinder installation

Record • Date list

c ng and outeii casing) Disassembling of upper half casing

I

• Casing alignment record (top on

Pre-• M/S, H/R pipe welding

u the upper) casing lug

• Cylinder high temperature bolt and mainj steam inlet flange bolt tightening record • Atmospheric valve installation record • Data list

• Oil retainer installation record

• Coupling runout record

• Rotor alignment record • Coupling installation record (betweenhigh and medium pressure and low pressurerotor A) • Coupling installation record (low pressure •otor A and low pressure rotor B) • Concentricity record of rotor connecting coupling Journal uplift record Key installation record

• Coupling installation record (recorded if needed) • Coupling bolt processing • Fitting bolt adjustment • Fitting bolt balancing

• Coupling runout check

• Rotor alignment record

• Coupling installation record

• Coupling hood clearance record

• Sensor installation record

• Thermocouple pre-installation

• Disassemble bearing

• Configure all equipment bypasses

• Install cooling pipe

• Perform oil flushing • Clean the main oil tank``

Final installation

Reference levelness check

High pressure/A, B low pressure final

alignment

B low pressure/generator

final alignment

Turbine/generator coupling reaming

High pressure/A, B low pressure and B low pressure/generator

coupli n g conn e c ti ng

Installation of auxiliary equipment

Installation of insulation layer

Preparation for oil flushing

1 Initial oil flushing

• Second oil flushing

• Flushing record and judgment

• Remove temporary pipe

•Record oil system orifice dimension

• Fill operating oil • Sufficient oil circulation • Preparation for final oil flushing • Final oil flushing

• Preparation work • Blow wash main steam pipe and steam manifold • Criteria for steam blow out

Second oil flushing

Bearing resetting

Final oil flushing

Steam pipe blowing

Reinstallation after steam pipe blowing

Reference levelness check

Vacuum lifting test

• :

III Installation Procedure

III-l Installation of Foundation Bolt and Bed Frame

After the primary grouting is finished, install the foundation bolt and bed frame. Before installing the

foundation bolt and bed frame, it is necessary to confirm that that the central axis and elevation of the

turbine generator unit and the condenser center position are correct.

When the bed frame is installed, it should be supported by concrete pillar. In this case, it should be

ensured that bed frame and concrete pillar are closely joined and the concrete pillar and the operating

floor primary grouting layer are firmly combined. Then install the bed frame and low pressure outer

casing and gradually extend to the generator side and the front bearing housing side. At the same time,

install, adjust and pre-tighten the foundation bolts.

Reference drawing Remarks

1. Confirm turbine generator unit,condenser centerline

Determine the center and elevation of the turbine generator unit and condenser with reference to the reference line of the power building and clearly mark them for easy alignment.

2. Check foundation bolt sleeve and embedded parts

Before roughening the foundation surface prior to secondary grouting,check the position and quantity of all foundation bolts and embedded parts against the drawings.

3. Foundation surface roughening prior secondary grouting

Bed frame mounting position needs to roughen the foundation surface.

Surface roughening work should be done according to the dimensions shown in the drawings and it should be ensured that foundation reinforcement is not exposed.

After surface roughening work is finished, cut off the foundation bolt sleeve head along the roughened su r fa c e. _____________

No. Work content Record

Roughening surface depth Cut off 20mm sleeve head

Operating flooi platform

Foundation

bolt sleeve

Work content

4. Bed frame positioning

Pull the music wire to mark the central

axis of the turbine generator unit based on

which to determine the position of the bed

frame.

5. Adjust bed frame levelness

Use the adjusting screw provided on the

bed frame to adjust the bed frame

levelness and then use the foundation bolt

to fix the bed frame.

6. Place concrete pillar

According to the distance between bed

frame and concrete pillar, use wood or

plastic template to make the shape of the

concrete pillar and then place the concrete

pillar according to the service

performance of cement materials. (Note:

trial placemetn should be made before

formal placement and the requirements of

the ""Installation Specification for

'Foundation Bed Box' of Turbine and its

Auxiliary Equipment" should be met.

7. Correct concrete pillar for bed frame

After cement pillar is completely cured,

remove the bed frame and grouting

template and confirm that concrete pillar

is already closed combined with the

operating floor roughened surface. Also

check the contact between bed frame

bottom surface and concrete pillar and if

necessary, trim the concrete pillar surface

so that the bed frame and c oncre t e p illa r

are well c o nta c te d .

No. Remarks Record

Overflow outlet

Refer e nce dr a w ing

Adjusting screw

Placement

port Placement template

Overflow chute

(The material for the bed frame pillar of theturbine generator unit is MF870C)

Work content

to install the low

pressure outer casing

Remove the jacking screw at the

bottom of the bed frame and

re-mount the dowel pin according to

the bed frame dowel pin erecting

drawing and then fix the grouting

baffle.

Check the distance from the top

surface of the bed frame to the

condenser throat and the levelness

and elevation of the top surface of the

condenser throat flange.

Weld the foundation bolts and nuts

exposed from the bottom surface of

the operating floor as shown and

mount the lifting screws to tht top end

of the foundation bolts.

9. Record bed frame levelness

Record the accurate levelness of

all bed frames of the turbine

generator un it . _______________

Remarks Record Reference drawin g No.

8. Prepared

bed frame

operating ^ket floor

\ Tack welding

1

Foundation bolt

condenser

throat

III-2 Installation of Low Pressure Cylinder

The instillation of the low pressure cylinder is closely related to the installation of the condenser. Before the low pressure outer casing is installed, the condenser upper part, shell and low pressure heater must be positioned, because once the low pressure outer casing is installed, these parts can not be installed. Therefore, the low pressure cylinder must be erected after these parts are installed.

It should be vary careful when erecting the low pressure cylinder, because the position of the low pressure cylinder is the basis of turbine generator unit alignment and once it is determined, the centerline of the whole turbine generator unit is determined accordingly.

As the low pressure outer casing is splice-welded from steel plate and tends to deform very easily, residual stress should be avoided on the low pressure outer casing in general assembling.

It is noteworthy that when the upper half of the low pressure outer casing is installed and the upper half is placed on, it is necessary to make the low pressure cylinder center consistent with the foundation center.

The lifting work subsequent to low pressure cylinder position should be extremely careful and it should be lifted according to the equipment lifting standard. Be very careful not to damage the part of connection to the high pressure cylinder.

In normal cases, the unit front, back, right and left are defined by a person standing at themachine head and facing the machine No. Work content

1. Check the contact between A and B low pressure outer casing bed plates The low pressure outer casings, after cleaned, are erected in turn along the turbine side. After installation, check the contact and clearance between casing bed plate and bed frame and confirm that the casing bed plate and bed frame are contacted evenly. 2. Preparation work for installation of low pressure outer casing Prepare the key, fix the connecting pieces connected to the condenser and check the oil line. 3. Erect lower halves of low

pressure outer casings A and B

end. Record Reference drawing Remarks

Low pressure outer casing

Horizontal joint

© Lower half of turbine side low pressure outer casing © Close to the lower half of turbine side low pressure outer casing ® Close to the lower half of motor side low pressure outer casing © Lower half of motor side low pressure outer casing

III-2 Installation of Low Pressure Cylinder

The instillation of the low pressure cylinder is closely related to the installation of the condenser. Before the low pressure outer casing is installed, the condenser upper part, shell and low pressure heater must be positioned, because once the low pressure outer casing is installed, these parts can not be installed. Therefore, the low pressure cylinder must be erected after these parts are installed.

It should be vary careful when erecting the low pressure cylinder, because the position of the low pressure cylinder is the basis of turbine generator unit alignment and once it is determined, the centerline of the whole turbine generator unit is determined accordingly.

As the low pressure outer casing is splice-welded from steel plate and tends to deform very easily, residual stress should be avoided on the low pressure outer casing in general assembling.

It is noteworthy that when the upper half of the low pressure outer casing is installed and the upper half is placed on, it is necessary to make the low pressure cylinder center consistent with the foundation center.

The lifting work subsequent to low pressure cylinder position should be extremely careful and it should be lifted according to the equipment lifting standard. Be very careful not to damage the part of connection to the high pressure cylinder.

In normal cases, the unit front, back, right and left are defined by a person standing at themachine head and facing the machine No. Work content

1. Check the contact between A and B low pressure outer casing bed plates The low pressure outer casings, after cleaned, are erected in turn along the turbine side. After installation, check the contact and clearance between casing bed plate and bed frame and confirm that the casing bed plate and bed frame are contacted evenly. 2. Preparation work for installation of low pressure outer casing Prepare the key, fix the connecting pieces connected to the condenser and check the oil line. 3. Erect lower halves of low

pressure outer casings A and B

end. ________________________________________________ Record Reference drawing Remarks

Low pressure outer casing

Horizontal joint

© Lower half of turbine side low pressure outer casing © Close to the lower half of turbine side low pressure outer casing © Close to the lower half of motor side low pressure outer casing © Lower half of motor side low pressure outer casing

jleference drawing

12. Tighten the vertical joint face bolts

of the low pressure outer casing upper

half

The vertical joint face bolts of the low

pressure outer casing upper half are

finally tightened, the deformation

prevention bracing of the outer casing

upper half is cut off and the horizontal

joint bolts are temporarily tightened.

13. Back off horizontal joint bolts

14. Check the horizontal joint clearance

Back the horizontal joint bolts and

check joint clearance. At this moment,

the joint clearance should be the same

as delivery state.

15. Disassemble the upper half of the

low pressure outer casing

16. Install the low pressure inner casing

and its locating key

17. Music wire alignment

No. Work content Record Remarks

III-3 Installation of Bearing Housing After the low pressure cylinder is positioned (top on) and music wire alignment is finished, start to install the intermediate bearing housing and then install the front bearing housing (For the installation method of the intermediate bearing housing, refer to the installation method of the front bearing housing). Adjust the contact and clearance between the sliding pin system sliding block and sliding block groove according to the installation requirement and ensure that the front bearing housing can slide freely with the expansion of the high and medium cylinders after the high and medium pressure cylinders are connected to the front bearing housing. ___________

Work content Record

seal parts of the front bearing housing oil pipe Install the front bearing housing oil discharge pipe according to the drawing and install the flange and seal ring together on the bed frame. 2. Preparation work procedure for installation of front bearing housing is as follows: Reinstall the sliding bock and key, tighten the foundation bolt and hold down the bed frame. Remove the front bearing housing cover and install the adjusting part in the front bearing housing to the original position. 3. Front bearing housing contact check Put the front bearing housing on the bed frame and check the contact of the front bearing housing sliding block and the horizontal joint levelness. 4. Adjust the bed frame height With the low pressure cylinder centerline (top on) as reference, add or remove shims between bed frame and concrete pillar to adjust the front bearing housing elevation. 5. Adjust the front bearing housing

position the front bearing along the determined Adjust the front bearing

housing position based on the center determined with the low pressure parts according to the dra w in g . _______

Shim

No.

1. Install the Referen c e drawin g Remarks

Axially housing centerline.

Work content

the front bearing

Confirm the clearance around the front bearing housing oil pipe and the clearance between the key and keyway to prevent interference due to front and back and right and left movement of the front bearing housing. Then install the front bearing housing hold-down plate.

Check the adjusting parts in the front bearing housing As the front bearing housing cover is not put on until the general assembling is finished, it is necessary to carefully check and protect the adjusting parts in the front bearing housing and the pipe openings in the housing should be sealed.

8. Install the oil piping in the bearing housing

ix the pipe when welding and painting the pipes.

Fix the front bearing housing Before installing the high and medium pressure outer casings, use the temporary supporting bolts on the two sides of the bed frame to firmly fix the front bearing housing to prevent its shift when the high and medium pressure outer casings are installed.

10. Adjust the front bearing housing hold-down plate gasket Adjust the gaskets under the front bearing housing hold-down plate to ensure that the freely inclined.

No. 6. Install housing

move axially and is not front bearing housing can

III-4 Installation o f High and Medium Cy lind er P a r ts

Work content Record Reference drawing

1. Turnover of the lower half of high

and medium outer casings

After cleaning the high and medium

outer casing lower half lugs, turn over

the lower half of the high and medium

outer casings.

2. Installation preparation of high and

medium pressure outer casing lower

halves

1) Prepare the supporting key and

longitudinal key and used for the lower

half of high and medium outer casings

and the connecting bolts between the

casings and bearing housings.

2) Prepare the casing lifting tools.

Install the lower halves of high and

medium pressure outer casings

4. Install the high pressure inner

casing, medium pressure inner

casing and steam seal body

Install the steam seal body and high and

medium pressure inner casings.

Measure the high and medium cylinder

joint levelness.

5. Alignment after temporary

supporting of high and medium

pressure cylinder lower halves

Align and position each of #1~#6

searings with music wire and

check each bearing t w i c e . __________

No. Remarks

III-5 Cylinder Alignment (Top-On Alignment)

Daring alignment, maintain the cylinders and surrounding environment in stable condition, because any change may affect alignment.

During alignment, avoid vibration of music wire.

All alij ming works should be done by one person to avoid human error. No. Work content Record Reference drawing Remarks

1. Preparation for alignment

Before alignment, install the joint

bolts, every three holes, to ensure that

the joint clearance is eliminated.

Install all bolts near the lug.

After these bolts are tightened, the

high and medium pressure cylinders

should be supported by the upper lug. 2. Install the music wire

Determine the positions of #3 and #6

bearings and then install the music

wire along this center from behind the

front bearing housing to #6 bearing.

Check twice the measuring

dimensions of all the positions that

should be checked. 3. Recheck the music wire

Confirm the music wire again and

recheck twice the measuring

dimensions of the positions that

should be checked. 4. Alignment record

Measure the distance between

respective measuring points and the

music wire respectively and record

the data and positions in the

certificate.

Work content

5. Verify the cylinder position

Check the cylinder horizontal joint levelness and compare it with the factory documentary evidence to determine whether the cylinder installation state is appropriate. Confirm that the cylinder horizontal joint coarseness is acceptable.

6. Determine the cylinder position

When the center of the unit high and medium pressure parts is found inaccurate, adjust the shims under the front bearing housing bed frame for alignment. Then repeat above 4, 5 and 6.

7. Complete cylinder alignment

Install the music wire and measure twice each data to be measured at the measuring positions and record them as required.

8. Lug sagging record

After cylinder alignment completed, i s

check lug sagging

Install the longitudinal key at the two ends of the low pressure cylinder

Adjust the clearance between ongitudinal keyway plate before and after the low pressure outer casing and the longitudinal key to be left and right equal and weld the longitudinal keyway plate. Install adjusting shims and accurately adjust the clearance. Then install the lock cover plate.

10. Disassemble the cylinder upper half

No. Record

III-6 Cylinder Alignment (Half Empty Cylinder)

After all cylinder lower halves are positioned, weld the connection between corresponding pipes and

valves and weld the connecting positions between low pressure cylinder and condenser. It should be

noted that welding deformation will occur during welding.

After the cylinder upper half is removed, carry out half empty cylinder alignment and confirm

that the difference between top-on alignment and half empty cylinder alignment is in the

allowable ran g e. ______________

No. Work content Record Reference drawing Remarks 1. Check of top-on alignment After cylinder and corresponding pipe and valve and condenser are connected, use the music wire to align. Compare the difference of these pipes, valves and condenser before and after installation and record it in the alignment card. 2. Alignment correction To reduce difference, you can knock the welded position and if necessary, cut off the pipe for correction (note: do not adjust the music wire). 3. Replace the key To disassemble high and medium pressure cylinders, first install the supporting key between the high and medium pressure cylinder lower half lugs and the front bearing housing and take out the key under the high and medium pressure cylinder upper half lugs. While this work must be carried out according to the above procedure and no difference is allowed. 4. Remove cylinder upper half After alignment is approved and completed, remove the joint bolts. Measure the clearance of horizontal joint of inner and outer casings (this clearance value is the final clearance value of the casing horizontal joint ) . __________

No. Work content Record Reference drawing Remarks

5. Levelness check of horizontal joint

Check the axial level of the high and

medium cylinder and low cylinder

joint. Measuring tools should be edge

ruler and level meter (this data is the

final data of the cylinder horizontal

levelness).

6. Top off alignment

Confirm that top-off alignment data is

in the allowable range specified in the

machine certificate.

7. Evaluation for top-on

alignment and top-off alignment

The difference between top-on

alignment data and top-off alignment

data is in the allowable range.

8. Final top-off alignment

Record and store top-off alignment

data.

III-7 Rotor Alignment

After cylinder alignment (to-on alignment and top-off alignment) is completed, use the turbine rotor to

replace music wire and start rotor alignment.

As rotor alignment and adjustment are completed on the supporting bearing, the bearing babbit metal

surface should be thoroughly cleaned and no scratch and scar is allowed on the be a r i ng b a bb it me t al

su r fa c e .

No. Work content

1. Bearing installation

Install #1~#6 bearings, check contact and

clearance of each bearing and supply

turbine oil to each bearing to check

whether oil feed and discharge positions

of each bearing are correct.

2. Lift the rotor

The rotor should be slowly lifted up and

always kept level.

In any case wire rope sling and lifting

position should meet the regulations of

the drawings and wire rope position also

should conform to the drawings and

should not be changed at will.

Wire rope should collide with other parts

to avoid damaging important rotation

positions.

Rotor should be lifted with the lifting

tool so that the rotor is in level state.

Put the rotor in the cylinder and

support it with bear i ng s . ____________

Reference drawin g

Install the upper bearing half

Check the parallelism of rotor journal

and bearing babbit metal surface and

check play between journal and bush

and their assembling.

Tighten bearing and bearing cover bolts.

4. Check the rotor center position

Check the position of the rotor at each

bearing oil retainer and compare the

check result with the certificate.

5. Correct the rotor position

When the bearing position needs

adjustment, first lift the rotor and then

adjust the cushion block under the

bearing bush sleeve.

At the same time, confirm that the

cushion block is well contacted and

bearing oil supply and return

positions are correc t . _____________

Remarks No. Record Work content

III-8 Diaphragm Alignment

After rotor position check and preliminary coupling alignment are completed, install and align the

diaphragm.

During diaphragm alignment, find a relatively short reference line in each cylinder as reference.

The position for diaphragm alignment is the same as that for rotor alignmen t c he c k .


1. Install the music wire

Erect a music wire between #1 and #2

oil retainers, #3 and #4 bearings, and #5

and #6 bearings as the centerline for

alignment of high and medium pressure

cylinders and low pressure cylinders A

and B.

2. Diaphragm alignment

Check and record the lower diaphragm

alignment (for reference line) reading.

The check method is the same as

cylinder aligning method.

All diaphragms should be aligned into

the tolerance range.

3. Steam seal body centerline check

Check the alignment of each steam seal

body centerline.

III-9 Diaphragm Alignment Adjustment

Diaphragm alignment is carried out in half cylinder but it should be noted that in this case the

weight of the upper cylinder half does not exist. Therefore diaphragm center position must be

ad j usted to substitute the design position with the com p ensation pos i t i on. _______________________ No. Work content Record Reference drawing Remarks 1. Adjustment principle SHIH ^/^^̂ SHIH (KB

1-1 For the high and medium

pressure parts, adjust the shims under

the lower casing lug and use this shim to

support the lower half of the outer

casing.

1-2 For the low pressure part, adjust the

supporting shim and use this shim to

support the lower half of the inner

casing.

2. Check again the diaphragm

position and confirm that the design

position has been compensated.

3. Re-adjustment of diaphragm

alignment

This work is done if re-alignment is

needed.

111-10 Flow Passage Clearance Check

After rotor position check and re-alignment are finished, measure the clearance between the rotor and

the stator which can not contact each other in actual operation.

There are three types of clearances, i.e. axial clearance, radial clearance and steam seal axial clearance,

and each type of clearance needs to be obtained correctly and precisely.

These three types of clearances, after measured, should be reported to the Dongfang Turbine Works

quality inspector for approval.

The following points should be noted in clearance measurement:

1. The axial clearance cannot be measured until the axial locating key of the thrust bearing is fitted.

2. As the rotor is installed in narrow and small space or between diaphragm sets, it is critical

to maintain accurate levelness and position (axial and radial). _________________________________ No. Work content Record Reference drawing Remarks

1. Preparation for rotor clearance

measurement

Prepare slope feeler gage and keep the

feeler gage and diaphragm contact

surfaces in proper contact. 2. Thrust bearing

Assemble the thrust bearing and

measure joint and clearance. Leave the

lower bearing half at the assembling

position for rotor lifting. 3. Adjust rotor position

Push forward the rotor till the allowable

position of the thrust bearing. Rotate the

rotor to have the assembling mark reach

the left position 50mm higher than the

horizontal joint. 4. Measurement of axial clearance

Use the slope feeler gage to measure the

axial clearance of all stages without

omission. All clearances should be

measured twice to ensure data

reliability.

5. Rotate the rotor to measure clearance

Rotate the rotor to zero position so that the

assembling mark is in the same position as

the left horizontal joint, and then measure

clearance "N" each time turn the rotor for

90°.

For the low pressure exhaust stage blade,

measure the clearance between guide vane

and blade top.

6. Measurement of steam seal axial clearance

Measure the axial position of the steam

seal long tooth, measure the clearance

between each long tooth of the steam seal

and the end face of the rotor boss at the

corresponding position and record the

measuring result.

7. Measurement of axial clearance and

other clearance

Measure the axial clearance and other

clearance specified in the drawings.

8. Rotor lifting

Remove the thrust bearing and the upper

halves of all supporting bearings and lift up

the rotor slowly and maintain its levelness.

In any case wire rope sling should be the

type specified in the drawing and its

position should be the same as shown in

the drawing and should not be changed at

will. The wire rope should not touch its

parts and components to avoid bruise of

important rotating parts.


9. Preparation for installation and measurement of the lower half of steam steal ring Install the lower half of the steam seal ring and use the process block to push it to the contact surface in exhaust direction. At the same time, use wedge block to fix the arc section of the steam seal from the right and left so that it will not sink. 10. Lead wire clearance measurement at the bottom Place lead wire on all the lower diaphragm halves in the axial direction and also place lead wire on all radial labyrinth strips. Lift the rotor onto it and measure the clearance by measuring the compressed thickness of all lead wires. 11. Lead wire clearance measurement in the upper part After the rotor is placed, install and fix the steam seal ring to the upper diaphragm half and the method is the same as installing the lower half steam seal ring. Install the upper half of each pair of diaphragms onto their lower half and measure the clearance by measuring the compressed thickness of all lead wires. 12. Clearance recording Record the top, bottom, right and left clearances at each steam seal in the clearance table and record other clearances in the record paper.

Work content Record

13. Positioning of main oil pump

Measure and adjust all clearances of the

main oil pump and then drive in the

locating pin to fix the position of the

main oil pump.

14. Positioning of emergency

governor

Measure the clearance between all

moving parts and finally fix the

emergency governor.

No. Referen c e drawin g Remarks

III-ll Adjustment Before grouting, carefully clean up foundation top and spray water to the foundation. When grouting work starts, it is necessary to work continuously until grouting is finished. It should be particularly pointed out that it is extremely difficult to grout the space under the front bearing housing bed frame and therefore grouting work should be done with spare caution to ensure the space is full of mortar.

For this reason, pay special attention to mixing ratio of the mortar and proport i on. _________

Work content

of foundation retaining plate

Align and install the foundation retaining plate and expose reinforcement and weld it to the retaining plate to avoid retaining plate movement during grouting. In addition, cut off and grind support column flat to prevent them from exposing out of grouting surface But do not cut off the support column of the generator, because they will be moved away during adjustment and alignment.

2. Alignment of low pressure cylinder side foundation bolt Remove the nuts from the foundation bolts at the low pressure cylinder and use the tapered wedge to adjust each foundation bolt to make it in line with the sleeve anc fixed.

3. Foundation cleanup the concrete

front bearing low pressure pay special

concrete oil or

Carefully dress and new concrete surface exposes.

It is necessary to clean up those areas covered by the bed frame and use compressed air to thoroughly remove concrete debris and sand and foreign matters around the foundation.

especially water

Remarks No.

1. Installation

Record Reference drawing

Grout pad

Carefully foundation

clean up at the

and and

the by

housing end cylinder end attention to contaminated

areas other chip substances.

until


4. Spray water

Before grouting, spray water to concrete

surface to maintain sufficient moisture.

5. Prepare for pouring template

Prepare and install the pouring template

to divide grouting areas.

6. Confirm the ratio of cement, sand,

gravel and water

When grouting, use vibrator or similar

tool to prevent cavity in the grout

blanket. After concrete grout is poured,

at least leave the grouting area more

than 3d.

Remarks Work content No.

111-12 Final Assembling

Confirm the following matters in final assembling:

(1) All parts and assembling parts need to be thoroughly cleaned up;

(2) All bolts for parts and assembling parts should be correctly connected;

(3) All positions that need lubrication should be applied with lubricant or grease.

Never drop unrelated materials or tools in the lower half assembling parts of the turbine.

To prevent foreign matters or dust from entering the turbine, the assembling work cycle should be as

short as possible.

Work content

whether the hold-down

bolts of the lower half of the lower

pressure inner casing are tightened.

2. Check the height of cushion block on

the suspension pin of the lower

diaphragm half.

3. Check whether the bolts of the lower

half of the shaft seal body are tightened.

4. Rotor check

(1) Clean and check rotor blades

(2) Check shroud band

(3) Supply oil to bearings

(4) Mount the rotor and measure again

rotor clearance at position

(5) Install the thrust bearing as well as

thrust block and thrust pad

5. Assemble the upper bearing half

Install the upper halves of all bearings

and temporarily install the upper halves

of the thrust bearing to m ake p r ep a ra t i on

for oil flushing .

Reference drawin g

(7> tAsnm *W

Remarks Record No.

1. Check

6. Install oil retainer

Clean up the lower half of each oil retainer and install it.

(1) Clean up bore area

(2) Check comb teeth of each oil retainer

(3) Use oil sealant

(4) Measure and adjust the right, left and bottom clearance of the oil retainer and rotor

(5) Check and install the upper half of each oil retainer.

7. Assemble

diaphragm

(1) Clean and wipe clean each pair of diaphragms

(2) Clean and check tooth groove before

inserting the steam seal arc

(3) Clean and check steam seal arc

(4) Install each steam seal and calk the locating pin

(5) Apply lubricant to the two sides of the

seal key in the horizontal position of each

pair of diaphragm.

(6) Install the upper half of each pair of diaphragm

(7) Bolt the upper and lower halves of each pair of diaphragms (apply lubricate to thread)

8. Assemble the upper half of the steam seal body

(1) Clean all parts of each steam seal body

(2) Apply to linseed oil to horizontal position

the upper half

. (3) Apply lubricant to thread of the bolts

used to tighten the upper and lower halves

(4) Tighten the upper and lower halves mutually

(5) Put the assembled upper half steam seal body onto the lower half and shift it outwards (to avoid interference with low pressure cylinder in assembling)

(6) Completely install the upper half steam seal

9. Assemble the upper casing half

(1) Clean and check cylinder and diaphragm upper halves

(2) Mount guide pillar on the lower half of the inner casing

(3) Lift up the upper casing half and keep it level

(4) Mount the upper casing half via guide pillar onto the lower casing half and measure the distance between upper and low half casing flanges at four different points. Be careful not to damage guide pillar and other parts during installation.

(5) When the distance between the upper and low half joints is less than 500mm, apply linseed oil to the upper half joint.

(6) Install the locating pin of the horizontal joint.

(7) When tightening the bolts, prevent wrench from falling into the casing.

(8) After completely tightening the joint bolts, install the steam seal body.

(9) Insert the reamed hole bolts into the horizontal joint holes of the steam seal body and then tighten the ve rti ca l j o i nt bolt s .

111-13 Final Alignment (HIP/ALP/BLP) This alignment work is very important and care must be taken to reduce serious consequences due to alignment error.

When the measuring data at rotor center and in the surrounding area meet the requirements directly connect the coupling and measure the coupling runout data.

After the above work is completed, ream the

.

1. Preliminary work

(1) Check the mark "G" on the external

surface of HIP/ALP and BLP rotor

couplings.

(2) Adjust HIP/ALP/BLP rotor so that the

mark "G" of these rotors are distributed

180° apart mutually.

(3) Supply high viscosity oil to each bearing.

(4) Install dial indicator to check the

position of the turbine rotor.

2. Alignment preparation

While keeping the same gap at the end

faces of the two coupling halves insert the

coupling bolts (erection bolt) and jacking

bolt and rotate two rotors.

Use crane and wire rope to lift the coupling

to rotor the rotor. The rotation direction

should be the specified turbine rotor

rotation direction.

As the rotor may have been deformed

after prolong placement, it is necessary to

first rotate the rotor more than 5min and

start measurement after gate reading

becomes stable.

coupling holes and install

Temporary thrust

b

stopper plate

Thirst plate o f 1 —L turbine rotor is also usas thrust bearing.

and tighten coupling

Chopper

l "

PARIS NO. Protection

plate

Ho* to apply I d i a l

Work content

3. Measure alignment accuracy

For each 1/4 turn of the rotor, measure the

clearance at four points (top, bottom, right

and left) on the coupling end faces and

record the measuring results as the

circumferential measuring results. Rotate

the rotor a complete turn and record the

measuring results at the top, bottom, right

and left of the circumference.

Decide the area to be moved according to

the above records to control the alignment

accuracy in the allowable range.

4. Connect the coupling

Clean up the end face between the two

coupling halves and apply molybdenum

disulfide lubricant to the sledge pin

connection. Do not leave any substance at

the direct contact area.

First mount the temporary taper pin into

the turbine-motor coupling connecting

four bolts in sequence to make the

coupling end face closely join.

5. Deviation measurement

After the two coupling halves are

connected, measure deviation at the

evenly spaced 12 points on the

circumference of the turbine and motor

end coupling and record the value.

No. Reference drawing

GEN rotor

Sheet packing

G"

F •G" KAIK

tul itge med for

Record

■aasorinr runout ofouter el rwriferenee

Remarks

GEN rotor

hole and then insert four bolts into the four

equally spaced holes. When rotating the

rotor with the crane, slightly tighten the

T.B rotor

T.B SIDECOUPLING

GEN SIDE CO

Work content

6. Hole honing (if necessary)

After all couplings are connected, if any

hole is found to be displaced, hone it till

meet the requirements while ensuring

that the coupling hole will not become

oval.

7. Prepare fitting bolt

Measure reamed hole diameter in

ongitudinal and horizontal directions and

machine the outside diameter of reamed hole

bolts and make its clearance less than

0.03mm in the diameter direction. After the

bolts are machined, weigh bolts, nuts and

washers and choose, combine and adjust to

make the weight difference of each set of

bolt nut less than 5g. All sets of bolts should

be numbered respectively after selected. 8

Alignment connection

Carefully clean each part and component and

apply molybdenum disulfide lubricant to the

thread of each nut. Mount and tighten the

bolts as required. Before tightening, use the

extensimeter to measure bolt length and then

tighten the bolts to the corresponding to

elongation and lock the bolts with lock

washers.

9. Install the coupling hood

Fix the coupling hood, measure the

clearance between the hood and rotor

and adjust the clearance to the specif i ed

value .

Record No.

111-14 BLP-GEN Final Alignment

Confirm whether connection of HIP/ALP/BLP has caused the alignment of BLP-GEN to

change and if so, perform final alignment for BLP-GEN. __________________________

Reference drawin g

1. Check and adjustment of BLP-GEN

final alignment

During BLP/GEN final alignment, check

the mark "G" which should be the 180°

opposite position on the two coupling

ends.

Check and adjust the alignment between

BLP/GEN and the method is the same as

the alignment between HIP-ALP and

ALP/BLP rotor couplings as described

abo v e .

Remarks No. Record Work content

f T

Position Left Top Right Bottom 1 2 3 4

Total Average

Note:

1) Unit: mm;

2) Circumferential runout is measured with dial indicator and end face is checked with inside micrometer;

3) "Left" and "right" are defined by the left and right hand directions of the observer who stands in front of

the turbine front bearing housing and looks at the generator end;

4) Dial indicator is installed on the turbine side rotor.

Each rotor should be measured for roundness and

runout and four points should be measured at each

position in the circumferential direction (90° apart

for two adjacent points).

111-15 BLP/GEN Coupling Reaming and Honing

After the final alignment is confirmed, if necessary, start the honing work for BLP/GEN coupling holes.

When preparing the bolts in the reamed holes, it is necessary to machine and test coupling bolt nut and this

work should be completed in the machining workshop and balance. Therefore it is necessary to determine

whether the machining workshop and balance can meet the need. (Dongfang Turbine Works has

completed the coupling reaming and couplin g bolt m achinin g w or k . I n principle, this wor k is n o t requ i r ed

to be done on si t e) .

Reference drawing

1. Direct connection of all couplings

(1) Clean up the surface between two

coupling halves and apply molybdenum

disulfide lubricant to the bore part.

(2) When connecting HIP/ALP anc

ALP/BLP couplings, mark "G" to the

excircle surface of the two coupling

halves.

(3) The marks "G" on the two adjacent

coupling should be 180 opposite angle.

(4) No other substance should be left on

the coupling end faces in direct contact.

Use the temporary taper pin to align

turbine end and motor coupling holes and

then insert one bolt every 90°, totally 4

bolts for the whole coupling, and mount

nuts.

Use the crane to lift and rotate the rotor

and then tighten screw pair little by little

until the contact surfaces of the two

coupling halves touch each other closely.

Tighten the screw pair and measure the

clearance between the contact surfaces

of the two coupling halves.

Record No. Work content Remarks

No. Work content

2. Runout measurement After direct connection, divide circumference of the turbine end and motor end couplings into 12 equal parts and measure and record runout value at the 12 equal parts.

3. Reaming

This process is only applicable to BLP/GEN coupling

The holes on the HIP/ALP and ALP/BLP have been completed in the factory and reaming is not need on site. For honing of all holes, refer to Item 6 of 111-13.

Confirm that the turbine end and motor end coupling holes are mutually aligned before reaming. At the same time, prepare a strong clamp to support ratchet indexing drill to ensure accurate hole position and round.

Reaming work shall be continued until the deviation between turbine end and motor end coupling holes disappears.

4. Preparation of bolts for reamed hole

Measure the reamed hole diameter in the longitudinal and horizontal directions and then machine the outsider diameter of the bolts for reamed holes so that the clearance between bolt and bolt hole is less than or equal to 0.03mm.

After the bolts are machined, weigh the bolts, nuts and washers and choose and combine them so that the maximum weight difference of each set of bolts and nuts is less than or equal to 5g. Print the numbers on each set of bolts, nuts and washers. The same set of parts use the same number.


turtlM X, Turtln.

inter

Remarks

Reference drawing

2. Turbine safety supervision device

Confirm that the tachometer, sensor,

expansion difference measurer and eccentricity measuring instrument in the front bearing housing are firmly installed in the correct positions and record the check results.

Use the same method to check the

upper expansion difference measurer. Also check the

performance of these instruments and confirm that they operate

normally.

3. Gasket replacement

Pull out the front bearing housing push and pull key and evenly jack up the lugs of the left and right cylinders. Pull out the front stop key and use the lower lug gasket to

replace the upper lug gasket. Then pull out the upper lug gasket and apply rust preventive oil and install it to the predetermined position. Pull the front bearing housing push and pull key back to the original

condition.

4. Tighten the hold down bolt in front of the high and medium cylinders

Mount the hold down bolt to the

front lug of the lower cylinder half

and apply lubricant to the thread. Tight the nuts and then mount and lock the lock nuts.

Record No. Work content Remarks

Work content Record

5. Assembling of front bearing housing cover

Check and confirm that the parts in

the housing have been installed and

preparation work for oil flushing has been completed.

Apply sealant to the joint to prevent oil leakage.

6. Install the center key of the high and medium pressure cylinder upper halves

Mount the center key between the

high and medium pressure cylinders and front bearing housing upper halves but do not completely lock it, because it needs to removed and

cleaned after oil flushing.

Connect the water spray pipe

Water flush and install the spray nozzle and tightly lock the union joint.

8. Install inner casing hand hole cover

Check and confirm that steam

extraction port blind flange etc has been installed with handhole cover

and bolts have been tightened and locked.

9. Install the atmospheric valve

Note the following in installation:

1) Spacer pin is embedded;

2) Copper plate is not defective;

3) After copper plate is mounted, check the clearance between knife

edge and copper plate.

Reference drawing No.

Work content

10. Install the outer casing manhole cover plate

As it is needed to go through the manhole for inspection after steam seal pipe etc. is purged, the outer casing manhole cover only needs to be installed temporarily.

11. Install the high pressure cylinder dynamic balancing hole blind flange

Install the dynamic balancing hole blind flange for the upper half of the high pressure cylinder. As the blind flange is a high temperature part, lubricant should be applied to thread.

After lubricant is applied to the inner casing shoulder, mount screw plug to the oil filler.

12. Install the shaft vibration probe

Temporarily install the shaft vibration probe and confirm the connection. These probes are

installed and adjusted after oil flushing and should b e p r o tecte d .

No.

111-18 Preparation Work for Oil Flushing

The purpose of oil flushing procedure is to remove welding splashing, chip and scale etc remaining in the oil piping, channel and oil sump to prevent damage and abrasion of the bearings and regulating system.

Please refer to the description of oil flushing procedure. _______

R e f e r e n ce d r a w i n g

1. Bearing disassembling

Remove the upper half of each bearing and connect a temporary bypass pipe which is led out from the oil supply hole of the lower bearing half.

For thrust bearing, remove gasket and thrust pad.

2. Connect the temporary oil flow observing pipe

Remove a branch pipe from the bypass pipe and install the temporary oil flow observing pipe and mount a mesh hood (100 and 120meshes) to the outlet end of the temporary piping.

Remove the throttling orifice.

3. Emergency governor

Remove the emergency governor and install temporary piping and valve so as to flush the emergency trip oil piping.

4. Main oil pump

Leave a small gap between horizontal flange surfaces of the oil pump case and let oil eject (about 5mm ) .

Work content Record No. Remarks


5. Main stop valve and combined reheat valve

(1) Disconnect the oil chamber pipe

connector between the main stop valve and combined reheat valve and the valve case.

(2) Mount the connecting plate to

the pipe connector matching surface

(3) Please refer to the electro hydraulic control oil flushing procedure.

6. AC start oil pump

Use 40~60mesh wire net to wrap the suction oil filter and provide temporary pipe for each piping.

7. Auxiliary oil pump and emergency oil pump

Use 40~60mesh wire net to wrap the oil filter.

8. Temporary pipe of booster oil pump

Remove the booster oil pump from

the oil tank and install the temporary

pipe for each connecting pipe.

9. Oil filter

Install the 60~100mesh wire net to

the oil tank return oil pipe.

10. Temporary pipe for compressed air. Mount a temporary pipe to the booster pump base and install c h ec k val v e t o t h e t e m p o r a r y p i p e.


11. Device internal cleaning

Each device should be internally cleaned thoroughly until bare hand can not touch viscous foreign matters.

12. Supervisory instrument

Please refer to the oil flushing piping system drawing.

XCI-1.2 600MW SCHEMATIC DIAGRAM FOR OIL PLUSHI KG

SAMPLEL

SUCTIM OIL pimp OIL row PIMP

CONDITIONER

1

MM

A OIL

C0UPLI!)Q

COOLING Sfl sos no

i"l"LP .. IESET CYLI.YDEI

*ES*jRft

TUMtXO

. A*LP

K /I ml

MAIH OIL PUMP

Mm EWICCNGT

iiii

/

N 71 HO not llfl TOMIST MAI I

KM 110

A A

/ \

4

COUPLING COOIIHO ^

ma iio

1KbTO JU7 IM

cTO N06 110

L E G E N D

COOLING IATEI LIHE FEED OIL LIHE TEMPORARY PIPE 01IFICE REDUCER NON-RETUIN VALVE SOLENOID-OPERATED VALVE

STRAINER IITN ORIFICE BOI PRESSURE GAUGE

CCOPIIHG COOLING

»«9.ffig

'PJH-M-

^

I IK

.JDA

J

JSA.

IF* !

IT

J41i

------

—4— o—-«-

9 1

1!

111-19 First Oil Flushing

Oil flushing is a process step prior to trial operation. Its purpose is to remove foreign matters remaining in the oil passage and oil system. Especially when oil temperature change leads to pipe expansion and shrinkage, the impurities adhering to the internal pipe wall will mix into the oil.

This process step is to use oil circulation to flush relatively heavy and large impurities without temperature rise.

Please refer to the description o f o il fl u s h i n g p r o cess .

Work content Record

1. Oil circulation

When oil is not heated but oil

temperature reaches 30~40°C, start

the flushing oil pump (either AC start oil pump or auxiliary oil pump) and make oil circulate for 1hr and

check oil leakage.

2. Oil circulation of AC start oil pump piping

Changeover of oil flushing piping should be controlled by the valve between the temporary pipes on the booster oil pump base. Oil circulation shall last at least 4h.

Main oil pump oil supply pipe Front bearing housing Main oil tank

3. Oil circulation to AC start oil pump piping

Main oil pump suction pipe Front bearing housing Main oil tank

Oil circulation shall last at least 4h

4. Oil circulation to AC start oil pump piping

Turbine bearing piping (#1~#6

bearings and thrust bearing)

Oil circulation shall last at least 6h.

Remarks Reference drawing

Bearing oil flushing 1.

Step 1

(1) Remove strainer from the orifice plate

(2) Install temporary pipe and control valve

(3) Install temporary blind plate in the orifice plate box

(4) Install temporary collecting bag

No.

(Diuttll Oil Onml hln

■riiMPiiu.


5. Adjust inlet oil amount of each bearing

Use the valve installed on each

bearing bypass pipe to adjust the inlet oil amount of each bearing.

6. Remove the strainer on the lube

oil filter on the bearing box

Remove the strainers on all oil filters to increase inlet oil amount.

7. Supply of compressed air

Increase oil pressure 0.5kg/cnT for

oil circulation by supplying compressed air continuously for 1 hr(Compressed air pressure must be higher than oil pressure 0.5kgf/cm ).

8. Knock the pipe

In oil circulation, use the hand

hammer to knock each pipe so that impurities on the internal wall come off.

9. Oil tank blow down

Transfer oil to the oil storage tank and use finer strainer to filter the oil

to remove the impurities mixed in the oil.

10. Cleaning of oil tank and oil sump

Clean the return oil pipe strainer and clean the strainer on the AC start oil

pump and auxiliary oil pump suction

oil pipe. Remove residual dust on the oil tank pipe, oil tank wall and in the

piping. Use wash leather other than cloth.

No. Work content

11. Oil filling

Inject the oil in the storage tank into the turbine oil tank.

12. Recording

When making oil circulation for oil flushing, check oil circulation condition every 30min and record it according to the following requirements.

(1) Oil discharge pressure of AC start oil pump and auxiliary oil pump;

(2) Oil discharge pressure of the regulating system and main oil pump;

(3) Oil pressure of bearing system;

(4) Inlet oil pressure of main oil pump;

(5) AC start oil pump and auxiliary oil pump motor temperature;

(6) Oil tank oil temperature;

(7) Oil tank level;

(8) Compressed air pressure;

(9) Cooling water pressure and temperature;

(10) Current of AC start oil pump and auxiliary oil pump;

(11) In this stage the basis for judging whether oil flushing is c o m p leted is t h e o il ci r culatio n time .

111-20 Second Oil Flushing

(1) The range of flushing pipe for this time is the same as the first oil flushing;

(2) Start oil pump and auxiliary oil pump are used;

(3) Oil cooler is used to reduce oil temperature;

(4) Please refer to the description of oil flushing procedure. _____________

Work content

1. Oil circulation of bearing oil piping is the same as the first oil flushing.

Additionally, due to high oil

temperature, compressed air is used

and pipe is knocked by hammer.

2. Temperature reduction

Pump oil into the bearing pipe for oil circulation. Oil temperature is

reduced by using the oil cooler for

cooling water circulation.

3.Record

Record the oil cooler inlet and outlet oil temperature as well as other items required in the first oil flushing, which are used to supervise oil circulation condition.

4. Oil tank flushing

The oil tank inside should be flushed

at least once every 70h.

5. Judgment for oil flushing completion

Install a lOOmesh wire net on the oil

filter in each bearing oil supply pipe

and after 4h oil circulation, visually check the lOOmesh wire net.

R e f e r e n ce d r a w i n g

Bearing oil flushing

1.Step 2

(1) Remove strainer from the orifice plate

(2) Remove temporary pipe and control valve

(3) Install temporary bearing bypass and control valve in the orifice plate box

(4) Install temporary collecting bag

Record No. Remarks


>& Criteria for evaluation

1. Conventional inspection:

pipes are free ftrhe

objects such as sand, rust and metal debris etc. and a tiny amount of soft

objects such as paint, cloth chip and

burr is allowed. Size of foreign matters should be less than

0.25mm except iron chips.

2. Sampling inspection

(1) Sampling position

Take inspection oil sample from the

main oil tank.

(2) Sampling time

Take samples after the second and

Third oil flushing.

(3) Each sampling inspection is performed twice.

(4) Inspection reference (2) Control oil: <NAS6

NAS etc

9 10 11 12

128000 256000 512000 1024000

22800 45600 91200 182400

4050 8100 16200 32400

720 1440 2880 5760

128 256 512 1024

0

JOP no

om internal hard

6

16000

2350

506

90

16

7 8.

32000 64000

5700 11400

1012 2025

180 360

32 64

0

JOP yes

00 0 1 2 3 4 5

5—15 125 250 500 1000 2000 4000 8000

16~25 22 44 59 178 356 712 1435

NAS Standard (National Aerospace Standard 1638)

Grain size

26—50

51-100

101-250 5=251

4 8 16 32 63 126 253

1 2 5 6 11 22 45

0 0 1 1 2 4 8

o

NAS standard

Reference drawing Remarks

(1) Bearing oil supply: <NAS8

111-21 Bearing Resetting

Remove the oil filter from the bearing oil piping and restore all pipes completely to the original installation state. Please refer to the description of oil flushing procedure.

Work content

1. Check of lower bearing half

Before resetting each bearing to its original state, remove the lower half of bearing bush and confirm that no foreign matter exists between rotor and bearing bush.

(1) Jack up the rotor and install bearing bush parts;

(2) Use the jack to jack up the rotor;

(3) Lift up the bearing bush and remove it;

(4) Check and remove foreign matters;

(5) Reset the lower half of the bearing bush to the original installation state.

2. Bearing assembling

This is the final assembling work for bearings and therefore bearings should be assembled one by one correctly and accurately.

When the bolt is tightened, the lock gasket locks the bolt.

Generally, such locking can be used three times but should be judged according to the actual locking condition.

3. Installation of accessories

Install thermocouple and adjust.

No.

111-21 Bearing Resetting

Remove the oil filter from the bearing oil piping and restore all pipes completely to the original installation state. Please refer to the description of oil flushing procedure.

Work content

1. Check of lower bearing half

Before resetting each bearing to its original state, remove the lower half of bearing bush and confirm that no foreign matter exists between rotor and bearing bush.

(1) Jack up the rotor and install bearing bush parts;

(2) Use the jack to jack up the rotor;

(3) Lift up the bearing bush and remove it;

(4) Check and remove foreign matters;

(5) Reset the lower half of the bearing bush to the original installation state.

2. Bearing assembling

This is the final assembling work for bearings and therefore bearings should be assembled one by one correctly and accurately.

When the bolt is tightened, the lock gasket locks the bolt.

Generally, such locking can be used three times according condition.

3. Installation of accessories

Install thermocouple and adjust turbine supervisory instrument etc. Especially as the thermocouple is installed to the rotor supporting area, it must be locked firmly and [ r e l i a b ly

No.

65

but should be judged to the actual locking

Work content

4. Reinstall bearing cover and coupling hood

Carefully check and clean up the inside and assemble them as quickly

as possible. Remember to note down clearance with oil deflector.

5. Adjust oil piping

Restore the piping around the governor and other devices to the originally installed position and confirm that the connection is not loose.

Confirm that locking is satisfactory and lock it according to drawing requirements. Do not lock the pipe connector nut by welding.

6. Oil tank resetting

Discharge all oil from the oil tank and restore the internal pipes and other temporarily provided parts and components to the original position to obtain the final assembling state.

Clean the oil tank and lock the parts and components that should be locked.

Remove the oil cooler and check its inside.

No.

111-22 Final (Third) Oil Flushing

Generally, the first and second oil flushing uses flushing oil (different from operating oil) but

the final oil flushing uses the operating oil (i.e. the oil used in actual operation).

Please refer to the description of oil flushing procedure.


1. Oil filling

Fill the oil tank with oil as quickly

as possible through oil filter.

2. oil pump operation

First start the auxiliary oil pump and

then start the AC start oil pump for

carry out oil flushing.

Check the total amount of foreign matters at the orifice box, bypasspipe, oil discharge port and temporary filter and

flushing condition.

3. Oil flow

Wrap the orifice plate in a layer of

lOOmesh strainer and let oil flow

through as long as possible

remove impurities.

If flowing time is insufficient, never

put the turbine into operation.

t

111-23 Steam Pipe Blowing

Steam pipe blowing should be carried out before steam is supplied to the turbine first time. Its purpose is to discharge various weld slag, iron chips and rust etc from the steam pipes.

The steam pipe blowing conditions can be: steam pipe blowing duration should be at least 6times pipe flushing duration so that the pipe flushing force ratio (C.F.R) in operation is greater than or equal to 1.

Please r e f e r t o t he g l a nd s t ea m f l u s h i n g p r oc e dur e . _____

Reference drawing

1. Blind plate installation

The following areas that do not need steam blowing are sealed with blind plates.

(1) Main stop valve stem leakage, 2 points;

(2) Combined reheat valve stem leakage, 2 points;

(3) Regulating valve step leakage, 4 points;

(4) BDV valve stem leakage;

(5) Ventilation valve stem leakage;

(6) SSR outlet end;

(7) Safety valve (SV).

2. Temporary pipe

(1) Use temporary pipe to connect steam supply pipe and steam discharge pipe for #1 and #2 shaft seals;

(2) Use temporary pipe to connect

steam supply pipe and steam discharge pipe for #4~#7 shaft seals;

(3) Connect the temporary pipe to the suction pipe of the steam seal heater to discharge steam to the atm o sp h er e .

No. Record Work content Remarks

3. Pipe blowing

(1) The blowing pressure of the auxiliary steam pipe is 15~20kg/cm2

and its residual pressure is used to

blow the main steam pipe, cold and hot reheat stem pipes. (2) To increase steam flow speed

and force during pipe blowing, the pipes are divided as follows. Blind

plate (non-operating blind plate) is

inserted into the pipes to carry out steam pipe blowing operation. Steam supply pipe for #1 and #3shaft seal blowing

Steam supply pipe for #4~#7 shaft

seal blowing

111-24 Resetting after Steam Blowing

After steam blowing and before oil pressure test, reset the main valves to the originally

installed positions.

In this case, it is very important to prevent steam leakage.

Note: when the valves are finally assembled, consider the operating sequence to ensure that the assembling work can be completed in the same day (The purpose is not to leave the opening overnight to avoid ingress of foreign matters into the opening).


1. Main stop valve

(1) Clean up the inside of the main stop valve body

Clean the inside of valve seat and drain port and clean the valve inside.

(2) Check contact.

Apply red lead to check the contact between valve disc and valve seat and use soft oil stone to grind the contact surface to ensure the required contact.

(3) Valve stem boss

Apply red lead to check its contact with the seal ring and if necessary, grind the contact surfaces on the two sides and face up the two surfaces.

(4) Valve seat and valve case assembling

Install the metal wound gasket and tighten the lower flange.

Apply molybdenum disulfide lubricant to the joint.

(5) Strainer installation

After installation, confirm that the installation position is appropriate and strainer bottom surface and valve case join closely.

(6) Valve cover installation

Check the depth at the seal and the thickness of the metal wound gasket and determine the compression d e g r e e . _____________________

Work content Remarks No.

Work content

molybdenum disulfide to the seal surface and

crane lubricate (a high viscosity oil) to bolt and nut thread

(7)Hot tightening of bolts

© Before tightening, use the bolt extensimeter to measure bolt length;

© When the bolt is not heated, tighten the bolt and measure flange clearance;

® Measure bolt elongation;

© Decide nut arc of rotation;

© Heat the bolt for hot tightening and cooling;

Measure and record bolt elongation and flange clearance;

(8) Valve stem connecting part

When the valve stem is connected to the oil servo motor connecting part, note the connecting part clearance and install limit stop and lever.

2. Combined reheat valve

(1) Clean up the inside of the combined reheat valve body

Clean up the inside of valve seat and drain port and clean up and check the inside of combined reheat valve

(2) Check valve seat contact

Apply as thin red lead layer as possible to check the contact between valve disc and valve seat as well as contact between valve stem and seal ring.

If the contact is not ideal, it should be ground with soft oil stone.

(3) Valve step assembling _________

Record No.

Apply lubricant apply

Remarks Reference drawing


Apply read lead to the contact with valve case matching surface and apply molybdenum disulfide lubricant to the seal surface.

(4) Connection of valve body, valve bush and valve stem

© Measure the clearance between valve bush and flange at the two ends and confirm that the measured value is the same as drawing dimensions.

© Check the two end clearance of the connecting rod matching with the valve seat and its value should be the same as the specified value in the drawing.

Apply crane lubricant to the thread of the straight pin.

Tighten the straight connecting pin and then lock it with lock washer.

3. Gland steam pipe

(1) Reset temporary pipe to the original position

Remove the temporary pipe connecting the gland steam supply pipe and exhaust pipe and reinstall the pipe to the original position.

Check the pipe installation bolt and confirm that each bolt is properly tightened and locked.

(2) Remove baffles

Confirm that all baffles mounted at the valve leakage are removed.

(3) Resetting of steam seal heater steam inlet pipe

Remove the temporary pipe and check the internal pipe and then

Reset it.

Use special care in heliarc welding to avoid foreign matters from being left in the pipes.

R e f e r e n ce d r a w ing Remarks

Appendix 1 T-G Foundation Embedded Parts Installation Manual

Contents

1. General

2. Installation record

2-1 Check parts

2-2 Mark off reference line

2-3 Install embedded parts

2-4 Install foundation bolt sleeves

2-5 Concrete placements

2-6 Final concrete placements

2-7 Final check of T-G foundation dimensions

2-8 Figure 1-Figure 3

1. General

(1) Scope

This installation manual is only applicable to the installation of T-G foundation embedded parts and foundation bolt sleeves. The work needs to be implemented by the professional contractor and participation of other organizations is not allowed.

This manual mainly introduces the technical problems for installation of T-G foundation embedded parts and foundation bolt sleeves and the normal problems (e.g. chamfer, cleanliness etc) are not introduced here.

In addition, this manual does not cover the working methods resulting from different tools and construction sequences.

Please carefully read this manual and completely understand its contents before actual work.

All works in this manual are implemented by the professional contractor. (2) The content and

use of this manual are composed of the following.

A. Flow chart and diagram

Flow chart and diagram indicate working sequence and also can be used as index.

B. Specifications

They are related to the formation of late stage working steps and as an outline describe the problems that should be noted in the works.

The first working procedure is carried out by steps according to the specifications.

All these steps should be recorded and relevant records should be submitted to Dongfang Turbine Works for approval.

C. About attached drawings

For better understanding of this specification, attached drawings are given in the last several pages of this manual.

(3) Precautions.

A. Completely understand the contents of the drawings before starting the complete assembling work.

B. Do not weld any area unless specially noted in the drawings.

C. Before assembling, remove all anti-corrosive agents applied before delivery.

D. Each day after work, cover the product with refractory board or waterproof board or the materials that can prevent equipment damage and rust formation.

E. When lifting the foundation bolt sleeve, align it to its installation hole and do not use wire rope to lower the sleeve.

2. Installation record

This manual has specially indicated the points that need to be recorded on site and the record should be correct.

Site record is divided into the following two types according to importance and can be properly adjusted properly according to the following requirements.

(1) Acceptance record

The record, after completion, should be immediately submitted to Dongfang Turbine Works (Mark "o" in the "Approval" column).

In examining these measuring records, sometimes other records are required.

When examining these measuring records, sometimes the data should be corrected.

Therefore, recording result should be immediately submitted to us so that we have enough time to correct them.

(2) Other records

The record should be complete and reliable and submitted together to Dongfang Turbine Works after completion.

Installation instruction of T-G foundation embedded parts and foundation bolt sleeves

When the foundation concrete is placed and embedded parts and foundation bolt sleeves are installed, they should not be moved at all.

Therefore embedded parts and foundation bolt sleeves should be installed to the accurate positions to easily match with the parts of T-G condenser and auxiliary equipment.

This work is relatively difficult because civil engineering and precision mechanical instruments must be used concurrently.

To easily determine the center position of the foundation bolt sleeves, the professional contractor needs to prepare the construction structure drawings.

All drawings must be collected together to prevent mistake in installation.

Concrete is poured after foundation bolt sleeves are installed.

After foundation bolt sleeves are installed, measure the center and height of each foundation bolt sleeve from the relevant reference line.

Before concrete placement, check whether its position is appropriate and record the measuring result.

2-1 Check parts

Before installing parts, check their quantity and dimension so that installation will not be interfered.

Installation record Remarks

Record

Approval

1. Parts classification

Parts are divided into two classes, i.e. embedded part and foundation bolt sleeve.

2. Check quantity

Check the quantity of embedded parts and foundation bolt sleeves according to the drawings and "Detailed List of Supplies":

(1) Arrangement drawing of turbine generator foundation embedded parts

(2) Arrangement drawing of turbine generator foundation bolt

(3) Detailed list of supplies.

3. Check parts dimension

Check the dimensions of each part and ensure no problem will occur after installation.

4. Embedded parts color classification

The contractor decides color classification details.

We recommend the following classification:

Foundation concrete is generally divided into 2-4 times placement and therefore, to facilitate concrete placement and differentiation, different colors are used in the drawings for identification. For example, colors are classified as follows and all parts should use the same color. In addition, it is recommended that the corresponding parts color is marked in the drawings.

• First time concrete placement area: brown

• Second time concrete placement area: orange

• Third time concrete placement area: yellow

• Fourth time concrete placement area: green

Note: For the parts that are not differentiated with color in the drawings, reserve enough space for their name and quantity to check the parts after embedded parts are installed.

2-2 Mark off reference line

The reference line is not only used to install embedded parts but also to install turbine generator, condenser and auxiliary equipment. Therefore, the calibrated measuring instruments are used and no error is allowed. Particularly centerline should be scribed with steel tools but this is not necessary for others.

Serial No., construction item and content

1. The centerline of turbine generator and condenser should be measured and scribed with power station reference as the reference point.

The first layer surface (bottom layer) centerline should be checked carefully and then it is ensured that steel plate is mounted in along the line.

2. Auxiliary reference line

With only turbine generator and condenser centerline and identification, it is difficult to check the installation position of embedded parts. Therefore auxiliary reference line is accurately marked in and out of the T-G foundation.

To facilitate subsequent embedded parts inspection, the above auxiliary reference line should be made and match with the reference line (centerline) on the T-G foundation drawing.

3. Reference line of vertical surface

Vertical surface=0" and it should be marked near the supporting pillar in the installation area. Each layer vertical surface should be marked with the same mark.

4. Check the verticality of the reference line

If the verticality of the reference line is inaccurate, T-G

condenser and auxiliary equipment can not be installed.

Therefore verticality check must be accurate and correct


Record

Approval

Figure 1

O

2-3 Install embedded parts

After cement foundation reinforcement and foundation bolt template are installed, the embedded parts are installed. When installing the embedded parts, fix them firmly to avoid their movement during unit operation. __________

Installation record

During laying out, centerline marking should be extended and exceeds the actual embedding range of the embedded parts.

2 Identification record

After marking on the template is finished, collect the position marking record and check whether it is consistent with the drawing.

Cut template

When the embedded parts are installed, if it is necessary to cut the template, appropriate measures should be taken, e.g. mark the identification line on the back.

4. Remove oil and grease

Completely remove oil and grease (including paint) from

the embedded parts so that they better join with concrete

5. Buried pipes

When pipes and other fittings are buried, the plug or pad

made of steel plate or similar material should be attached

to the pipe opening to prevent cement from entering the

Pipe-Drain pipe and similar pipe should have drain slope

and it is necessary to refer to the drawing to install them

to the positi on .

Serial No., construction item and content Record

Approval

1. Mark the position of embedded parts

Measure and identify the template surface reference line and determine the installation position of the embedded parts relative to the reference line.

Remarks

O

Serial No., construction item and content Record

App r ov al

6. Reinforce the embedded parts

Determine that each embedded part is well connected to a concrete reinforcement so that the embedded parts will not move or leave when concrete is placed (do not weld).

7. Installation tolerance of embedded parts

Unless specially noted in the drawings, the center dimension and installation tolerance of the whole embedded part should be within ±10.0mm (axial and vertical) and related dimensions are shown in the dra w i n g s . _____

2-4 Install foundation bolt sleeves

When the foundation bolt sleeves are buried in the cement foundation, never move them

Position the foundation bolt sleeves based on T-G and condenser centerline. Accurately install

and reinforce the foundation bolt sleeves so that they will not be dislocated due to concrete flow. In order to reinforce foundation bolt sleeves, they should be supported with stand column and wood plug (supplied by the contractor) other than cement foundation reinforcement. In addition, each foundation bolt sleeve should be arranged in the area where reinforcement will not be touched and sufficient clearance should be left between the two

Installation record

Approval Serial No., construction item and content

1. Check the reference line

Before installing the foundation bolt sleeves, check and the T-G and condenser centerline marked on the platform. Make sure that these reference lines conform to the T-G and condenser centerline marked on the foundation frame.

2. Check the verticality of the reference line. Check the

verticality of T-G centerline and condenser.

3. Centerline of foundation bolt sleeves

From the T-G and condenser centerline, calculate and measure the foundation bolt sleeve center and make i d e n ti f i c a t i on on the frame.


Record

O

Figure 1,2

O O

Remarks

Serial No., construction item and content Installation record Remarks

4. Check the verticality of foundation bolt sleeve centerline

Measure the centerline diagonal line length; the maximum difference between diagonal lines should not exceed 2mm.

5. Install foundation bolt sleeves Figure 3

Measure the axial and vertical distances and the verticality based on sleeve centerline and install each foundation bolt sleeve as shown.

6. Final check of foundation bolt sleeve position

After T-G foundation placement and foundation bolt sleeve installation are completed, it is necessary to finally check the reference line and sleeve centerline position and record the check result.

The chief person on site from Dongfang Turbine Works gives witness according to the above record.

If the chief person on site from Dongfang Turbine Works

is not present on site, the above records should be submitted to Dongfang Turbine Works for approval.

This process is a long period of time involving final record collection, certificate check, submission of record for approval, record return etc. Therefore in the beginning sufficient time should be reserved for this procedure.

7. Final check

(1) Check whether each foundation bolt sleeve is reinforced firmly.

(2) If any foundation bolt sleeve contacts concrete reinforcement, keep sufficient gap between foundation bolt sleeve and reinforcing bar.

(3) Check whether concrete reinforcement height is the same as drawing.

(4) Check whether sufficient gap is reserved between foundation bolt sleeve and template.

Record Approval

Figure 2

O

O

Figure 2 O

Serial No., construction item and content

(5) Check whether dust and foreign matters (wood chip, metal chip etc) have been removed on the template.

(6) Check whether sufficient gap is reserved between template and embedded parts.

(7) Check whether template dimension is the same as

shown in the drawing. (8) Check whether template is inclined.

2-5 Concrete placement

If concrete is placed only in one direction, template may be inclined or sink, thus it is necessary to place concrete evenly from different directions. During concrete placement, use bamboo stick and vibrator etc to fill each corner with concrete.

Serial No., construction item and content Installation record Remarks

Record Approval

1. Check before concrete placement O

(1) Before concrete placement, remove dust and foreign

matters (wood chip, metal chip etc) from the template.

(2) It is required that strength of cement main bar be specified and the specified strength borne by its material be determined. (3) Check and record template dimension and verticality. 2. Concrete placement height Concrete placement height should be predetermined and it is necessary to check whether the actual height of concrete placement is the same as the predetermined value. 3. Marking

After concrete placement and setting, mark the reference line for installation of embedded parts next time and install embedded parts. Marking specification of the reference line is the same as

2.


Record Approval

O

O

6 Final concrete placement

1. After final concrete placement, concrete surface should be chiseled for 50mm depth so that cement slurry for secondary grouting can completely adhere to the concrete. Therefore, it is necessary to measure the distance from concrete main bar to concrete surface to ensure main bar will not expose after surface toughening. In addition, the embedded part levelness of generator air duct must be within ±2mm (subject to generator requirements).

2. If concrete is placed in one direct, template may be inclined or sink or the main bar may be shifted to get in contact with foundation bolt sleeve.

3. During concrete placement, use bamboo stick and vibrator etc to fill each corner with concrete.

2-7 Final check of T-G foundation dimensions

After final concrete placement and setting, it is necessary to measure and record the following dimensions and send the record to Dongfang Turbine Works for approval.

(1) Reference line and foundation bolt sleeve centerline

(2) T-G foundation opening dimension.

(3) T-G foundation opening verticality.

(4) Locating dimension of foundation bolt sleeve.

(5) Verticality of foundation bolt sleeve.

(6) Locating

sleeve.

Condenser centerline (Floor 3)

T-G centerline (Floor 3)

centerline T-G centerline (reference line) (Floor 1)

Figure 1 (Type Fixing Drawing)

dimension of oil discharge pipe

.

®"\®

Cf) P-}^ T-G foundation

*7 ®Condenser

ference line) (Floor 1) '

(r

Check reference line verticality and measure diagonal length. Check method is as follows: If there is any difference between lines, e.g. difference between C-F and C-F' and C'-F',

it indicates that condenser centerline and T-G centerline are not at the correct angle

(not orthogonally).

T-G centerline (reference line)

feFoundation bolt sleeve center reference line

C3

Figure 2

Check the verticality of reference line.

(1) Condenser centerline

(2) Foundation bolt sleeve center reference line

Record the foundation bolt sleeve center position.

Measure and record the position dimension of each foundation bolt sleeve relative to reference line.

For example:

To condenser reference line: 1, 2, 3;

To T-G centerline: (a), (b).

Condenser centerline (reference line)

A-A'

B-B' and C-C

Frame

AFoundation bolt sleeve

Template

a

b

Figure 3 Installation of Foundation Bolt Sleeve

For the verticality of foundation bolt sleeve, it is necessary to measure the following dimensions and calculate their difference.

Part "a": dimension X-Y

Part "b": dimension X-Y

Workholding fixture

Plumb

(1) For details, refer to the relevant drawings.

(2) Foundation bolt should be welded to concrete reinforcement.

(3) Concrete should be grouted into the foundation bolt sleeve (grouted when turbine bed frame bed plate is installed).

(4) Use transit level to check the height of foundation bolt.

(5) Recheck the distance between foundation bolt and T-G, exhaust hood and motor center (also recheck diagonal length).

(6) Allowable tolerance for foundation bolt installation

A. Vertical direction-the top of foundation bolt is allowed to be 5~7mm higher than the shown height.

B. Horizontal direction-shown dimension ±lmm.

C. Orthogonal centerline-total length ±2mm.

Appendix 3 Regulations of Gas Shielded Welding for Connecting Lower Half of Lower Pressure Cylinder to Condenser

1. Scope

This instruction is used for the gas shielded welding for connecting the low pressure cylinder lower halt to the condenser. Unless other specially noted in this instruction, all welding shall meet the Chapter IX of ASME.

2. Preparation before welding

(1) At all workpieces that need to be welded in the condenser, erect a scaffold and connect batten root and then install handrail according to surrounding environment.

(2) Before welding, do the following work.

(3) Determine that the welders have the qualification specified in JIS or ANSI standard.

(4) Determine the groove dimension of the low pressure exhaust hood and condenser connecting shell. If the gap is too wide, the turbine proper may be deformed in welding and therefore the gap should be adjusted to be within the shown tolerance range.

(5) Before welding, determine the clearance of the matching surfaces of the supporting strips placed between the low pressure exhaust hood and condenser connecting shell. If there are two many ruffles, they should be polished or the condenser connecting shell should be welded to ensure groove dimension.

(6) Drill holes at 500mm pitch in the internal surface between the low pressure exhaust hood and condenser connecting shell. The drilling distance between the two in the vertical direction should be 120mm (See Figure 1 for details).

(7) Determine that the groove dimension of the welding area is in the shown tolerance dimension range. Make the groove shaped supports of appropriate sizes and install them on the low pressure exhaust hood at 600mm pitch (See Figure 2 for details).

Vertical measuring dimensions may be slightly longer or shorter than the post-weld dimensions.

Low pressure exhaust hood shell

Supporting strip

VI

Condenser connecting shell

[Figure 2]

3. Welding instruction

3-1 Welding needs to be performed by four welders according to the numerical sequence shown in Figure 3.

(1) Weld Point 1 point from four centers. Four welders start diagonal welding from the center in the opposite sides. When Point 1 is welded, the discontinuous welding length is 150mm and pitch is 50mm. Welding in this area directly affect the bearing part of the low pressure cylinder.

(2) Electrode should be low hydrogen electrode JIS-D4316 or other equivalent materials.

(3) After discontinuous welding is completed, the remaining welding part is about 50mm for each section.

(B)

© © © © © ( D © © © © ©

<®i i i

Turbine centerline i

111

(C)

< 2 > < Z > <0» < 5 > ' < S > <p> < D < S > <3> i

Figure 3

Low pressure exhaust hood shell

Supporting strip

Condenser connecting shell

[Figure 1]

Support

(A)

®

©

© 1©

©

©

©

©

© ©

©

©

©

©

©

<©

<5

<a>

<2>

(D)

Welding Instruction

3-2 After Point 1 is welded, weld Point 2 in the opposite direction and polish it.

3-3 In welding the exhaust hood, the welding distance should be adjusted accordingly from Point 1 to Point 3.

3-4 Therefore, the change of this distance should be carefully measured. 3-5 Point 4 and other

points of the exhaust hood should be welded continuously. Check any change frequently

during welding and observe and determine that everything is normal until all points are

welded.

3-6 To release stress, all points, after welded, should be polished with air hammer except the last point.

3-7 After all points are welded, check the foundation plate levelness record. 3-8 After each

point is welded, measure casing deformation, e.g. dimension "A" in Figure. Then adjust the

welding sequence based on the measuring result. For example if the dimension of a certain

part "A" is larger than the other parts after measurement, this part should be welded first.

3-9 After welding, measure the exhaust hood deformation at "B" (See Figure), which should be less than 7mm (See Figure 5 for details).

Outside

Exhaust hood iefore welding

Exhaust hood after welding

Figure 4 Welding Drawing

3-10 Welding sequence

Welding sequence is shown in Table 1:

Figure 5 Exhaust Hood Deformation

Table 1 Weldin g Sequence

Electrode diameter

l/8 " (3.2mm)

5/32"(4.0mm)

3/16"(5.0mm)

l/4"(6. 0 mm)

l/8"(3. 2 mm)

3-11 Electrode

The material equivalent to or better than "AWS" (>£ ©) in the table can be used.

All electrodes should be dried in electric oven at 300°C~350°C for lh (See Table 3).

__________________ Table 2 Electrode

Manufacturer's name

S-16(*@)LB-26(*@)

>*< © American Welding Society

>£© Japanese Steel Welded Product Engineering Co. Ltd (Japan)

*® Kobe Steel Ltd (Japan)

Table 3 Electrode Heating Temperature

Electrode heating temperature (°)

300-350

3-12 Welding and welding current

AC arc welding is used and welding current is shown in Table 4. Its current is related to electrode diameter.

Table 4 Welding Current

Electrode diameter (mm)

We l d i ng c urr e n t (A)

3-13 Preheating temperature

Determine the preheating temperature according to ambient temperature. See Table 5.

Point

Point 1

Point 2 and other points

La s t po i n t

Coating type

Low nitrogen

AWS

E7016(*©)

JIS

D4316

Coating type

Low hydrogen

H eati n g time

lh

3.2

80-120 130-170 230-280 170-220

Tab l e 5 Pr e h e at i ng Temp er ature Ambient temperature (°C) Preheating temperature (°C)

<20 20-50

>20 Preheating not needed

3-14 Welder's certificate

The welder must obtain ASME boiler and pressure vessel welding qualification certificate (in accordance with Chapter IX "Welder's Certificate" of ASME Boiler and Pressure Vessel Welding Code".

3-15 Weld inspection

Inspection should be carried out according to Appendix 8 "Dye Penetrant Test Method (PT)", Chapter VIII of ASME Boiler and Pressure Vessel Welding Code and the inspection

acceptance criteria are shown in Table.

____________________ Table 6 Inspe c t i on A cc e pt an c e C r i ter i a Acceptance criteria

Linear indication Defect indication

Maximum allowable Maximum allowable defect

diameter (mm) length (mm)

Unacceptable 01.0 30

3-16 Store the welding tools and put them orderly in the specified area. At the same time, sweep the condenser inside and remove scaffold.

Appendix 4 Combined Reheat Valve Connection Regulations

Contents

1. Scope

2. Instruction

3. Material

4. Welding material

5. Equipment


7. Welding joint alignment


9. Preheating and interlayer temperature

10. Post weld heat treatment

11. Weld check

12.Record

13. Document submission

14. Deviation

15. Appendix

1. Scope

This instruction is applicable to the site welding of combined reheat valve and high pressure outer casing. All welding shall conform to this instruction and Chapter IX of ASME Boiler and Pressure Vessel Welding Code (1979).

2. Instruction

Inert gas shielded arc welding (GTAW) is used and the second layer and subsequent layers are welded with shielded metal-arc welding (SMAW).

3. Material

3.1 Casing material

A. Combined reheat valve: Cr-Mo steel casting

B. High pressure outer casing: Cr-Mo steel casting

3.2 Material specification

This instruction is applicable to the following steep pipe diameter and wall thickness:

Steel pipe diameter: 640.0mm Steel pipe thickness: 58.0mm

4. Welding material

4.1 Fusion welding metal material

Root fusion welding metal is the AWS Class ER90S-G material in Part C Material Specification No.SFA5.28, Chapter II of ASME or other equivalent materials.

Fusion welding metal for other layers is AWS Class E9015-B3L material in Part C Material Specification No.SFA5.5, Chapter II of ASME or other equivalent materials.

Before welding, all electrodes are dried in the electric over at 300°C~350°C for 3h.

4.2 Shielding gas

^99.9% welding argon is used.

To protect weld during welding, argon flow needs to be maintained at 0.7m3/h.

5. Equipment

5.1 Welding motor

Gas tungsten arc welding (GTAW) uses DC motor.

Shielded metal-arc welding (SMAW) uses DC motor


6.1 Welding groove

The welding groove between the combined reheat valve and the high pressure outer casing is processed according to Figure 6.

6.2 Groove face

All groove faces should be undamaged and be removed of oil, grease, rust and foreign matters.

7. Welding joint alignment

7.1 Aligning method

Four supports are welded at A.l and A.2 between the combined reheat valve and the high pressure outer casing for positioning. See Figure for details.

7.2 Support

The support is made of 15~20mm thick low carbon steel plate.

7.3 Support welding

Before the support is welding, all welding areas should be preheated to 250°C~300°C with oxyacetylene welding torch.

First, weld the support to the high pressure outer casing (fillet weld, weld leg length 15mm) and cover the welding area with asbestos-free heat-insulating material to gradually cool to room temperature.

Then after the high pressure outer casing and support are cooled, place the combined reheat

valve to the outer casing and ensure that the groove root gap between the two is 4.1~4.3mm and center error does not exceed 0.5mm. Support welding needs to measure the groove root gap. After welding, the welding area is cooled using the above method.

After preheating according to 9, measure and ensure 3.5±0.5mm groove root gap. The best gap is 3.5mm.

When the gap exceeds 4.0mm or is too small, remove the support and re-position the combined reheat valve.

7.4 Remove support

After one layer is welded with gas tungsten arc welding (GTAW) and the second is welded with shielded metal-arc welding (SMAW), cut off the support connected to the casing and valve at 3mm from the flat plate.

After welding and post weld heat treatment are finished, polish the weld to perform dye penetrant inspection (PT) and magnetic particle inspection (MT).


8.1 General

Welding method is shown in Figure 5.

To prevent welding deformation, two welders should weld symmetrically.

8.2 Positioning

All areas should be satisfactorily positioned.

8.3 Root welding (Layer 1)

Root is welded with gas tungsten arc welding (GTAW) and welding area should be visually checked. Welding is performed after all defects are removed.

Any movement of reheating interception/stop valve during welding process shall be recorded.

8.4 Welding of other layers

All the other layers are welded with shielded metal-arc welding (SMAW). To prevent welding deformation, two welders should weld symmetrically and welding process should not be discontinued.

Increased weld height shall not exceed 3mm and the thickness is increased from edge to center.

Any movement of the combined reheat valve during welding should be recorded.

8.5 Weld polishing

The weld should be polished and undergo magnetic particle inspection (MT) after welding. The defects around the weld and its nearby area should be removed.

8.6 Welder's certificate

The welders must obtain the ASME Boiler and Pressure Vessel welding qualification

certificate (in accordance with Chapter EX "Welder's Certificate" of ASME Boiler and

Pressure Vessel Welding Code).

9. Preheating and interlayer temperature

9.1 Preheating

Preheating is controlled as per curve in Figure 2. Weldment temperature should be controlled at 250°C~350°C.

Once the temperature is lower than 250°C, immediately stop welding and re-weld after the temperature rises to the required value.

9.2 Heating method

>100kVA electromagnetic induction coil is used for heating. To protect workpieces, the coil is wrapped in the asbestos-free insulating materials, 8-10 layers, thickness >13mm. The width

of the insulation layers should be 20mm more than the coil width. For details, refer to Figure

3.

Totally 10-15 turns of electromagnetic induction heating coils are wrapped around each edge

of the working welding groove and heating width is 335mm.

The number of heating coils on the two sides of the groove should be the same.

9.3 Temperature measurement

Thermocouple is placed on top, bottom, left and right to measure temperature. The

thermocouple should be placed at the four positions close to the weld joint shown in B.l of

Figure 1.

10. Post weld heat treatment

10.1 Stress relief

Stress relief is controlled as per curve in Figure 4 and carried out using the electromagnetic

induction heating coils when or before the welding temperature drops to 250°C.

The width of the heating area is 3 times the welding area.

10.2 Temperature measurement

The thermocouple placed at C.l in Figure is used to measure temperature change. Temperature

gradient at C.l or C.2 and B.l should be lower than 80°C.

11. Weld check

11.1 General

After stress relief, weld surface is polished to \/ and undergoes PT, MT and RT inspection. For

its specification and acceptance criteria, refer to Appendix A.

11.2 Repair of defective weld

Defects around and near the weld should be removed and rewelded using the above method.

12. Record

Record should include:

(1) Electrode

(2) Welding motor and welding speed

(3) Preheating

(4) Interlayer temperature

(5) Post-weld heat treatment (including temperature, heating time, heating and cooling speed)

(6) Weld inspection result

(7) Welder's qualification inspection conclusion

13. Document submission

Welder's qualification inspection conclusion should be submitted to Dongfang Turbine Works before welding and if Dongfang Turbine Works requires submitting the other relevant documents, they should be submitted together.

14. Deviation

All deviations should be approved by Dongfang Turbine Works.

Appendix A Weld Inspection

1. Dye penetrant test (PT)

1.1 Inspection regulation

Penetration time: at least lOmin

1.2 Acceptance criteria

Crack not allowed.

2. Magnetic particle inspection (MT)


Magnetization: prod method

Magnetization time: 2s

Magnetizing current: 600-800A

Magnetic head distance: two orthogonal directions 150~200mm


Crack, undercut and mutual overlapping are not allowed.

3. Radiographic inspection (RT)


Execute ASMT standard of equivalent standard. Radioactive source should be placed to the

center of pipe and welding area and film placed on the circumferential surface (as shown in the

figure below).

kr- ------- r-^r. ___ dQ.

\ y^y

High pressure outer casing

w~m—cr


Allowable number of defects is 5. When defect length is less than 2mm, the number of defects is the actual number of defects; when defect length is larger than 2mm, the number of defects is the actual number of defects by converting coefficient in the following table.

Conv e rt i n g c o e ffic i e n t <2mm 2.1~4.0mm 4.1~6.0mm 6.1~8.0mm 8.1~10.0mm 10.1~12.0mm

1 4 6 10 15 20

Q

Metal plate (low carbon steel)^\

>& After the combined reheatv

valve and high pressure outer casing are welded, remove the metal plate.

Defect length

Converting

coefficient

Support

Figure 1

Site welding (low carbon teel electrode)

Shop welding (low hydrogen electrode)

15~20nn

Welding temperature 250~350°C

Stress relief circulation is performed according to Figure 4. Do not cool to room temperature.

Figure 2 Preheating

insulation material covering layer (8-10 layers) Coil (335mm wide)

Figure 3 Covering Layer

High pressure outer casing

<110°C/Hr

^250°C

690T+15T

Control stress relief after welding

<110T/Hr

<75°C/Hr

300°C

Then air cooled in stationary state with furnace

Figure 4 Stress Relief Circulation

Electrode

Diameter 2.4mm

Diameter 3.2mm

Diameter 4.0mm

Diameter 5.0mm

Before welding, all electrodes are dried in the oven at 300°C~350°C for 3h. All dirt and slag

in the weld between pipes must be thoroughly removed.

Final welding layer (stiffened)

Figure 5 Welding Technique

Horizontal joint

Support

Combined reheat valve

Figure 6 Welding Preparation

Process

GTAW

SMAW

SMAW

SMAW

L a y e r

T o L a ye r 3

Las t l a y e r

Vo lt a g e (V )

10-10

20-30

20-30

20-30

Current (A)

100-110

100-140

120-180

190-220

Turbine center

High pressure outer casing'

660mw Turbine (Dongfang)

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