GE SPS ID Fan Erection Sequence

Imagination at work

ID FAN ERECTION SEQUENCESURATGARH-(2X660 MW)

Prepared by: Suvendu Samal

See tutorial regarding confidentiality disclosures. Delete if not needed. 2Suratgarh -2X660 MW

INTRODUCTION• Fans are provided to control the flow of air or gas through equipment or through a series of components interconnected with a system of duct work. The fan increases the pressure of a flow stream to offset the pressure losses that result from system resistance.

•Types of Fan : Draft fans are classified as either Centrifugal or Axial, according to the direction of air or gas flow through the fans:

Centrifugal fans move air or gas perpendicular to the impeller shaft.

Axial fans move air or gas parallel to the impeller shaft.

See tutorial regarding confidentiality disclosures. Delete if not needed. 3

LIST OF ACTIVITIES

Suratgarh -2X660 MW

Sl. No. Activities Remarks1 Foundation take over2 Blue matching of sole plate motor and impeller housing3 Alignment of sole plate with respect to centre line as per

drawing4 Erection of suction chamber, impeller housing, diffuser

assembly5 Alignment and leveling of above wrt to center line6 Coupling Measurement & Heating (Oil Bath or Induction Heating)7 Erection of Motor with coupling8 Erection of Rotor assembly9 Alignment of Rotor assembly Alignment Steps:- a) Master Level of Rotor Assy (Tolerance: 0.04mm) b) Torquing of Rotor Assy with Housing Bullet c) level of Housing & Rotor Assy

10 Grouting of Housing Sole Plate11 Alignment of motor with rotor assembly12 Grouting of all sole plate and motor base plate13 Erection of expansion bellow suction and discharge side N.A14 Erection of Silencer assembly N.A15 LOS system piping and flushing16 Erection and alignment of blade pitch control power cylinder17 Erection of linkage assembly18 Erection of blades19 Alignment of blades with bottom impeller housing20 Erection of Seal air fan21 Cleaning of silencer and silencer hood22 Trial run of motor23 Final alignment of motor with fan


FOUNDATION CHIPPING

Suratgarh -2X660 MW


BLUE MATCHING OF HOUSING SOLE PLATE

Suratgarh -2X660 MW


SOLE PLATE LEVELNESS

Suratgarh -2X660 MW

MILL SOLE PLATE CENTRE LINE , FLATNESS AND ELEVATION CHECKING.


ERECTION OF SUCTION CHAMBER, HOUSING AND DIFFUSER

Suratgarh -2X660 MW

ERECTION OF DIFFUSER, BEARING HOUSING AND SUCTION CHAMBER.


BLUE MATCHING OF MOTOR SOLE PLATE

Suratgarh -2X660 MW

BLUE MATCHING OF MOTOR SOLE PLATE IS CARRIED OUT BY MEANS OF SCRAPING.


DIMENSIONAL CHECK OF COUPLINGS..

Suratgarh -2X660 MW

COUPLING MEASUREMENT BY INSIDE MICROMETER.


COUPLING HEATING

Suratgarh -2X660 MW

•The Coupling is heated by means of Coil heating.•The Coupling heating temperature is elevated up to 150*C.


COUPLING HEATING

Suratgarh -2X660 MW

•The Motor Shaft Coupling and Rotor Shaft Coupling are mounted on them respectively.


ERECTION OF ROTOR AND MOTOR

Suratgarh -2X660 MW

MOTOR AND ROTOR ERECTION.


RADIAL SEALING..

Suratgarh -2X660 MW

•The Copper radial sealing are mounted on the Bearing housing to avoid the fly ash to accumulate on the seating area of rotor and further to assist in free rotation of Rotor.


CHECKING OF ROTOR LEVEL

Suratgarh -2X660 MW

CHECKING OF ROTOR LEVELNESS WITH THE HELP OF SQUARE LEVEL.


ROTOR ASSEMBLY TORQUEING

Suratgarh -2X660 MW

TORQUEING OF ROTOR ASSEMBLY WITH HOUSING BULLET.


GROUTING OF SUCTION CHAMBER, BEARING HOUSING AND DIFFUSER

Suratgarh -2X660 MW

GROUTING OF SOLE PLATES OF BEARING HOUSING, DIFFUSER AND SUCTION CHAMBER.

•The shuttering work is carried out prior to grout of the sole plates. The Studs are protected from grout material by surrounding the studs with thermacol.• The Stud area is also filled with sand prior to grout in order to prevent the entrance of grout material.


ROUGH ALIGNMENT OF FAN AND MOTOR

Suratgarh -2X660 MW

• Motor Side • Rotor Side

•The rough alignment of Fan and motor is to carried out prior to grouting of Motor Sole plate.• Reading has to be taken for vertical and Horizontal run out and the maximum allowable tolerance to be kept at +/- 0.05mm.•Then after the rough alignment the hot alignment has to carried-out where the Horizontal run-out remains same and the vertical run-out is to be maintained as per specifications.

ROUGH ALIGNMENT OF FAN AND MOTOR PRIOR TO GROUT.


HOT ALIGNMENT OF FAN AND MOTOR

Suratgarh -2X660 MW

•This practice is to be followed for all Axial Flow ID Fans, mainly in Super Critical Design.

• In case of ID Fan (Axial) flow, as there is the Hot flue gas that flows through the Fan, it has to be Hot Aligned or in other words, the motor has to be off aligned.

• The Angular misalignment (due to thermal expansion of fan housing) at motor and fan side must be brought to right dimensions by alignment of Vertical and Horizontal dimension of Motor.


BLADE AND ACCESSORIES

Suratgarh -2X660 MW

• List of Items: Piston Ring,Spring Loaded Seal Ring, Bolt & Washer •The Blade bolts are to be torqued up to 750 Nm.


TYPE OF BLADES:

Suratgarh -2X660 MW

• Backward Curved Blades : These are normally the Airfoil type. The airfoil blade is widely used and has several advantages: Highest Efficiency, Low Noise Level, Stable Operation, Ideal Capabilities for high- speed service. The use of backward curved blades should be avoided on applications where significant levels of large or adhesive particles are present. • Straight Blades : These are sometimes called radial blades. The Advantages are:- Wide range of capacities, Good Abrasion resistance, Simplified maintenance, easy for blade replacement The disadvantage of straight blades is the relatively low operating efficiency and an overloading horsepower characteristics. • Radial Tip Blades : Radial blades are normally used for moderately erosive gas applications. The Advantages are:- High capacity for size, Excellent Abrasion resistance, Essentially self cleaning capabilities The disadvantage of radial tip blades is the efficiency is not as high as that of backward curved blades.


TYPE OF BLADES:

Suratgarh -2X660 MW

•Typical Forced Draft (FD) Fan Blade •Induced Draft (ID) Fan Blade


BLADE BOLT TORQUEING

Suratgarh -2X660 MW


BLADE TIP CLEARANCE

Suratgarh -2X660 MW

•Bearing Housing

12

3

4

56

7

8

• The Reading of each blade has to be recorded at the positions as note above inside the bottom of Bearing Housing and after Box-up the clearance from top of the Bearing housing to be recorded.• The above dimensions are necessary to find the longest blade from the given sets of blades been fixed on the rotor assembly.


LUBE OIL SKID

Suratgarh -2X660 MW


LUBE OIL STATION PIPING

Suratgarh -2X660 MW


LUBE OIL STATION PIPING ROUTING

Suratgarh -2X660 MW


LUBE OIL STATION PIPING LAYOUT

Suratgarh -2X660 MW

• The Piping Layout as indicated in the above slide, shows us there are 3 terminals been connected to Rotor Sump namely (RL)- Return Line/ Drain Line, (PL)-Pressure Oil Inlet Line to Main Bearing, (AL)- Air Expansion Line. These points are connected to the main bearing.• The Other 3 Terminal Points from the Lube Oil Station are connected to the HAD(Hydraulic Actuator Device)/ Servo.• The 3 points are namely (PH)- Pressure Oil Hydraulic, (LH)- Leakage Oil Hydraulic, (RH)- Return Oil Hydraulic.• The Main Purpose of the Oil Piping is to assist the Blade movement for Open/Close conditions depending upon the requirement of air flow.


ACID CLEANING OF LUBE OIL PIPING

Suratgarh -2X660 MW


PROCEDURE FOR ACID CLEANING OF PIPES

Suratgarh -2X660 MW

• Lube oil systems and its oil lines are erected fully as per approved drawing.• Lube Oil Lines are then dismantled and one end of each pipe is blocked by wooden plug or temporary blank flange. Tight fitting of the wooden plug or blank flange with gasket and bolt is ensured so that no leakage of chemicals occurs during acid cleaning process.• The dissembled pipeline pieces are filled with DM water and flushed few times. It is to ensure that there is no leakage through the wooden plug or temporary blank flange provided at one end of the pipe.• 5% Hydrochloric acid (HCL) solution is filled in the pipes. The solution is allowed to soak in the pipes for 04 Hours and then drained in a safe place and neutralized. The pipes are then flushed with DM water for 05 to 10 Minutes.• The Pipes are again filled with 05% liquid ammonia solution. The solution is allowed to soak for 30 minutes and then drained.• The pipe is rinsed with DM water and the Flushed water is Checked with Universal PH Indicator for a PH level in between 6.5 to 7.5.• The Internal surface of the pipes is dried with dry compressed air.• The lines are filled with Lube oil and uniform Oil film is achieved through out the internal surface of the pipe.

GE SPS ID Fan Erection Sequence

Documents

Transcript of GE SPS ID Fan Erection Sequence